Page:1 of 6 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

Scrap SG&A Profit ED&T-R&D

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

060700 Power Brake Subsystem ( for Hydraulics)

1 00 Vehicle Installation of Power Brake Subsystem (for Hydraulic) $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A Vehicle Installation of Brake Actuation Subsystem Components - Booster 06 07 00 - N0502- 01 1 Baseline $0 1

Includes Assembly of Booster 

Assembly Differences. Base has 

less assembly content and is 

considered baseline (i.e., $0.00)

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B Vehicle Installation of Brake Actuation Subsystem Components - Vacuum Pump 06 07 00 - N0502- 01 1 n/a 1 Not Applicable to Base Vehicle $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Sub-Subsystem

Part Number

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

System 

ED&T/R&D

(x1000)

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Technology Level: Power-Split HEV Technology

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 01 Vacuum Booster $ 6.30 $ 6.24 $ 4.87 $ 17.40 $ 0.09 $ 1.24 $ 1.12 $ 0.44 $ 2.89 $ - $ 20.30 $ -

A H Brake Booster Assembly Populated 06 07 01 - N0502- 01 1 See A.1 1

Master Cylinders were cost neutral - 

excluded from analysis. $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A.1 Brake Booster Assembly (Master Cylinder Removed) 06 07 01 - N0502- 02 1 Full 1

Unique Boosters between Base and 

HEV designs $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A.2 G - Brake Booster $ 2.29 $ 1.64 $ 1.18 $ 5.11 $ 0.03 $ 0.35 $ 0.32 $ 0.13 $ 0.82 $ - $ 5.94 $ -

A.3 G-Output Rod Assembly $ 0.10 $ 0.46 $ 0.86 $ 1.42 $ 0.01 $ 0.09 $ 0.09 $ 0.04 $ 0.22 $ - $ 1.64 $ -

A.4 G-Gear Assembly $ 0.02 $ 1.07 $ 0.42 $ 1.50 $ 0.01 $ 0.10 $ 0.09 $ 0.04 $ 0.24 $ - $ 1.74 $ -

A.5 G-Shell Rear w. Studs, Booster $ 0.96 $ 0.21 $ 0.58 $ 1.76 $ 0.01 $ 0.11 $ 0.11 $ 0.04 $ 0.27 $ - $ 2.03 $ -

A.6 G-Tie Rods w. O Ring, Booster $ 0.78 $ 0.04 $ 0.06 $ 0.88 $ 0.00 $ 0.06 $ 0.05 $ 0.02 $ 0.14 $ - $ 1.02 $ -

A.7 G-Nut w. O-Ring, Booster $ 0.24 $ 0.04 $ 0.07 $ 0.35 $ 0.00 $ 0.02 $ 0.02 $ 0.01 $ 0.05 $ - $ 0.40 $ -

A.8 G-Ceneter Assy, Booster $ 0.93 $ 0.78 $ 0.47 $ 2.18 $ 0.01 $ 0.17 $ 0.15 $ 0.06 $ 0.39 $ - $ 2.57 $ -

A.9 G-Valve Body Assy, Body $ 0.37 $ 0.77 $ 0.38 $ 1.53 $ 0.01 $ 0.14 $ 0.12 $ 0.04 $ 0.30 $ - $ 1.83 $ -

A.10 G-Input Rod Assembly $ 0.52 $ 1.17 $ 0.82 $ 2.51 $ 0.01 $ 0.17 $ 0.16 $ 0.06 $ 0.41 $ - $ 2.92 $ -

A.11 G-Key Booster $ 0.08 $ 0.06 $ 0.02 $ 0.16 $ 0.00 $ 0.02 $ 0.02 $ 0.01 $ 0.05 $ - $ 0.21 $ -

B1 H Nut, Cylinder to Booster 06 07 0 - N0502- 03 2 na 1

Cost Neutral between Base and 

HEV $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

3 02 Vacuum Pump and Motor $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A H Vacuum Pump Assembly 06 07 02 - N0502- 01 1 n/a 1 Not Applicable to Base Vehicle $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ $ - $ - $ $ - $ - $ - $ - $ - $ $ - $ $ - $ $ - $ $ -

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:2 of 6 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

Scrap SG&A Profit ED&T-R&D

Sub-Subsystem

Part Number

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

System 

ED&T/R&D

(x1000)

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Technology Level: Power-Split HEV Technology

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

4 03 TBD $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

5 04 Hydraulic Booster $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

6 07 Vacuum Reservoir and Distribution Components $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

7 10 TBD $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 60 Wiring Harness Connections Wiring Harness Connections $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ -

A Wire Harness Connector - Vacuum Sensor Brake Booster (5 pin) 06 07 60 - N0502- 01 1 n/a 1 Not Applicable to Base Vehicle $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B Wire Harness - Vacuum Solenoid, Brake Booster 06 07 60 - N0502- 02 1 n/a 1 Not Applicable to Base Vehicle $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

C Wire Harness - Booster Travel Sensor 06 07 60 - N0502- 03 1 n/a 1 Not Applicable to Base Vehicle $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

D Wire Harness - Vacuum Pump (2 Pin) 06 07 60 - N0502- 04 1 n/a 1 Not Applicable to Base Vehicle $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 70 Pipes, Hoses, Ducting $ 0.65 $ 0.23 $ 0.21 $ 1.09 $ 0.01 $ 0.10 $ 0.09 $ 0.03 $ 0.23 $ 0.02 $ 1.34 $ -

A H Vacuum Hose Assembly , Vacuum Pump/Intake - Booster 06 07 70 - N0502- 01 1 n/a 1 Not Applicable to Base Vehicle $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B H Vacuum Hose Assembly , T - Booster 06 07 0 - N0502- 02 1 Full 1 Not Applicable to Base Vehicle $ 0.65 $ 0.23 $ 0.21 $ 1.09 $ 0.01 $ 0.10 $ 0.09 $ 0.03 $ 0.23 $ 0.02 $ 1.34 $ -

10 75 Brackets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A H Bolt Vacuum Pump to Block 06 07 80 - N0502- 01 1 n/a 1 Not Applicable to Base Vehicle $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B H Nut Vacuum Pump to Block 06 07 80 - N0502- 02 1 n/a 1 Not Applicable to Base Vehicle $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 90 Bearings Elements Misc Bearings Elements Misc $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:3 of 6 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

Scrap SG&A Profit ED&T-R&D

Sub-Subsystem

Part Number

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

System 

ED&T/R&D

(x1000)

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Technology Level: Power-Split HEV Technology

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

$ 6.95 $ 6.47 $ 5.07 $ 18.49 $ 0.10 $ 1.34 $ 1.21 $ 0.47 $ 3.12 $ 0.02 $ 21.63 $ -

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

Complete Subsystem Quote 

(Yes/No) No

the competing technology

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:4 of 6 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0 n/a n/a

060700 Power Brake Subsystem ( for Hydraulics)

1 00 Vehicle Installation of Power Brake Subsystem (for Hydraulic)

A Vehicle Installation of Brake Actuation Subsystem Components - Booster 06 07 00 - N0502- 01 1 Baseline $0 1

Includes Assembly of Booster 

Assembly Differences. Base has 

less assembly content and is 

considered baseline (i.e., $0.00)

B Vehicle Installation of Brake Actuation Subsystem Components - Vacuum Pump 06 07 00 - N0502- 01 1 n/a 1 Not Applicable to Base Vehicle

Sub-Subsystem

Part Number

QTY/ Subsystem

Notes

Subassembly

Component

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Power-Split HEV Technology

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

2 01 Vacuum Booster

A H Brake Booster Assembly Populated 06 07 01 - N0502- 01 1 See A.1 1

Master Cylinders were cost neutral - 

excluded from analysis.

A.1 Brake Booster Assembly (Master Cylinder Removed) 06 07 01 - N0502- 02 1 Full 1

Unique Boosters between Base and 

HEV designs

A.2 G - Brake Booster

A.3 G-Output Rod Assembly

A.4 G-Gear Assembly

A.5 G-Shell Rear w. Studs, Booster

A.6 G-Tie Rods w. O Ring, Booster

A.7 G-Nut w. O-Ring, Booster

A.8 G-Ceneter Assy, Booster

A.9 G-Valve Body Assy, Body

A.10 G-Input Rod Assembly

A.11 G-Key Booster

B1 H Nut, Cylinder to Booster 06 07 0 - N0502- 03 2 na 1

Cost Neutral between Base and 

HEV

3 02 Vacuum Pump and Motor

A H Vacuum Pump Assembly 06 07 02 - N0502- 01 1 n/a 1 Not Applicable to Base Vehicle

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:5 of 6 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Sub-Subsystem

Part Number

QTY/ Subsystem

Notes

Subassembly

Component

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Power-Split HEV Technology

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

4 03 TBD

5 04 Hydraulic Booster

6 07 Vacuum Reservoir and Distribution Components

7 10 TBD

8 60 Wiring Harness Connections

Investment

(X1000)

Tooling 

(x1000)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

8 60 Wiring Harness Connections $ - $ -

A Wire Harness Connector - Vacuum Sensor Brake Booster (5 pin) 06 07 60 - N0502- 01 1 n/a 1 Not Applicable to Base Vehicle

B Wire Harness - Vacuum Solenoid, Brake Booster 06 07 60 - N0502- 02 1 n/a 1 Not Applicable to Base Vehicle

C Wire Harness - Booster Travel Sensor 06 07 60 - N0502- 03 1 n/a 1 Not Applicable to Base Vehicle

D Wire Harness - Vacuum Pump (2 Pin) 06 07 60 - N0502- 04 1 n/a 1 Not Applicable to Base Vehicle

9 70 Pipes, Hoses, Ducting

A H Vacuum Hose Assembly , Vacuum Pump/Intake - Booster 06 07 70 - N0502- 01 1 n/a 1 Not Applicable to Base Vehicle

B H Vacuum Hose Assembly , T - Booster 06 07 0 - N0502- 02 1 Full 1 Not Applicable to Base Vehicle

10 75 Brackets

11 80 Boltings

A H Bolt Vacuum Pump to Block 06 07 80 - N0502- 01 1 n/a 1 Not Applicable to Base Vehicle

B H Nut Vacuum Pump to Block 06 07 80 - N0502- 02 1 n/a 1 Not Applicable to Base Vehicle

12 85 Sealing Elements

13 90 Bearings Elements Misc

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

13 90 Bearings Elements Misc $ $ - $ $ -

$ - $ -

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:6 of 6 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Sub-Subsystem

Part Number

QTY/ Subsystem

Notes

Subassembly

Component

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Power-Split HEV Technology

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

14 99 Miscellaneous

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

Complete Subsystem Quote 

(Yes/No) No

Investment

(X1000)

Tooling 

(x1000)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

1. = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: H Vacuum Hose Assembly,Booster Part Number: 060770-B0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 ASSEMBLE VACUUM HOSE FITTING 060770-B0502-02 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 180 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.05 $0.08 $0.14 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.15 $0.15 $0.00

2

VACUUM HOSE FITTING, FRONT SHELL -

BASE 060770-B0502-02A 1 Mold T2/T3 Inject. Mold, SSLC

Nylon66, Inject.

Mold/Cast/Sinter Operator Inject. Mold, SS 1800 1 1 1 0.012 $1.74 $41.48 $16.39 $16.39 $0.02 $0.02 $0.01 $0.05 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.06 $0.06 $0.02

3

VACUUM HOSE FITTING, FRONT SHELL -

COVER 060770-B0502-02B 1 Mold T2/T3 Inject. Mold, SSLC

Nylon66, Inject.

Mold/Cast/Sinter Operator Inject. Mold, SS 1800 1 1 1 0.012 $1.74 $41.48 $16.39 $16.39 $0.02 $0.02 $0.01 $0.05 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.06 $0.06 $0.02

4

5 G-VACUUM HOSE ASSEMBLY, BOOSTER 060770-B0502-01 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 144 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.13 $0.10 $0.24 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.26 $0.26 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

D Purchase Part - Commodity ( Value taken from Purchase Part Database)

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 HOSE CLIP 060770-B0502-03 4 S $0.00 $0.03 $0.00 $0.12 $0.12

2

HOSE 5/16 VL OUTER - CR INNER - NBR ( 3 

1/4") 060770-B0502-04 1 0.041 @ $1.85/lb. S $0.00 $0.08 $0.00 $0.08 $0.08

3

HOSE 5/16 VL OUTER - CR INNER - NBR ( 9 

1/2") 060770-B0502-05 1 0.1396 @ $1.85/lb. S $0.00 $0.26 $0.00 $0.26 $0.26

4 MESH WRAP (5 1/8) 060770-B0502-06 1 .0264lb. .25/ft. S $0.00 $0.11 $0.00 $0.11 $0.11

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 

Mark-up Calculations.

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: H Vacuum Hose Assembly,Booster Part Number: 060770-B0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

5 VALVE 060770-B0502-07 1 S $0.00 $0.05 $0.00 $0.05 $0.05

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

7 0 $0.00 $0.00 $0.00 $0.00 $0.00

8 0 $0.00 $0.00 $0.00 $0.00 $0.00

9 0 $0.00 $0.00 $0.00 $0.00

Material

$0.65

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $1.14

T1 or OEM Total Manufacturing Cost: $0.65 $0.23 $0.21 $1.09 $0.00 $0.03 $0.02 $0.00 $0.05 $1.14

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

3

1

Notes: T1 or OEM Total Manufacturing Cost: $0.65 $0.23 $0.21 $1.09 $0.00 $0.03 $0.02 $0.00 $0.05 $1.14

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.07 $0.07 $0.03 $0.18

Base Cost Impact to Vehicle: $0.65 $0.23 $0.21 $1.09 $0.01 $0.10 $0.09 $0.03 $0.23 $1.32 $0 $0

Packaging Cost: $0.02

Net Cost Impact to Vehicle: $1.34

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 10 Cavity Mold 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

Purchase Part - High Impact Item (Full Cost Mapping)

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

ASSEMBLE VACUUM HOSE FITTING 060770-B0502-02

VACUUM HOSE FITTING, FRONT SHELL -

BASE 060770-B0502-02A

VACUUM HOSE FITTING, FRONT SHELL -

COVER 060770-B0502-02B

G-VACUUM HOSE ASSEMBLY, BOOSTER 060770-B0502-01

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.05 $0.08 $0.14 $0.00 $0.01 $0.01 $0.00 $0.01 Insert valve, apply adhesive and press base to cover 5 2 10 100 47 4700 96 37.60 85% 113 31.96 20 2 1 20 1.0 1.0

$0.02 $0.01 $0.05 $0.00 $0.00 $0.00 $0.00 $0.01 55-150 ton, 10 cavity mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 2 1 10 20 1.0 1.0

$0.02 $0.01 $0.05 $0.00 $0.00 $0.00 $0.00 $0.01 55-150 ton , 10 cavity mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 2 1 10 20 1.0 1.0

$0.13 $0.10 $0.24 $0.00 $0.01 $0.01 $0.00 $0.02 Bend, cut, slide on mesh protector and apply four clamps 5 2 10 100 47 4700 96 37.60 85% 113 31.96 25 4 1 25 1.0 1.0

Purchase Part - Commodity ( Value taken from Purchase Part Database)

HOSE CLIP 060770-B0502-03

HOSE 5/16 VL OUTER - CR INNER - NBR ( 3 

1/4") 060770-B0502-04

HOSE 5/16 VL OUTER - CR INNER - NBR ( 9 

1/2") 060770-B0502-05

MESH WRAP (5 1/8) 060770-B0502-06

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.12

$0.08

$0.26

$0.11

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

VALVE 060770-B0502-07

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.05

$0.00

$0.00

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$0.23 $0.21 $1.09 $0.00 $0.03 $0.02 $0.00 $0.05

$1.14

2

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

ASSEMBLE VACUUM HOSE FITTING 060770-B0502-02

VACUUM HOSE FITTING, FRONT SHELL -

BASE 060770-B0502-02A

VACUUM HOSE FITTING, FRONT SHELL -

COVER 060770-B0502-02B

G-VACUUM HOSE ASSEMBLY, BOOSTER 060770-B0502-01

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

180 20.00 0.25

1800 2.00 1.00

1800 2.00 1.00

144 25.00 0.50

Purchase Part - Commodity ( Value taken from Purchase Part Database)

HOSE CLIP 060770-B0502-03

HOSE 5/16 VL OUTER - CR INNER - NBR ( 3 

1/4") 060770-B0502-04

HOSE 5/16 VL OUTER - CR INNER - NBR ( 9 

1/2") 060770-B0502-05

MESH WRAP (5 1/8) 060770-B0502-06

#DIV/0! #DIV/0! -

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

VALVE 060770-B0502-07

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly ( Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 G- BRAKE BOOSTER 060701-B0502-02 1 Assemble T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 122 4 4 1 0.000 $0.05 $38.55 $15.00 $60.00 $0.00 $1.26 $0.49 $1.75 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.75 $1.75 $0.00

3

G-RETAINER, OUTPUT ROD

060701-B0502-04 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LC 277 0.25 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.03 $0.04 $0.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.07 $0.07 $0.00

4

G-RETAINER, OUTPUT ROD

060701-B0502-04A 1 Stamp T1 Assembly, Mark-up Applied 

@ Bottom. MC-Steel-1018, Bar Cut/Punch/Forming Operator Stamp/Form, XSS 6000 0.5 1 1 0.061 $0.74 $42.73 $24.60 $24.60 $0.05 $0.00 $0.00 $0.05 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.05 $0.05 $0.05

5

G-CLEVIS TO PEDAL

060701-B0502-05 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LC 277 0.25 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.03 $0.04 $0.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.07 $0.07 $0.00

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

5 060701-B0502-05 1 Wash @ Bottom. Not Applicable General Assembly Washing Equipment, LC 277 0.25 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.03 $0.04 $0.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.07 $0.07 $0.00

6

G-CLEVIS TO PEDAL

060701-B0502-05A 1 Machine T1 Assembly, Mark-up Applied 

@ Bottom. MC-Steel-1018, Bar CNC Operator CNC Machining, LC 212 0.5 1 1 0.220 $0.74 $36.98 $30.38 $30.38 $0.16 $0.09 $0.14 $0.39 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.39 $0.39 $0.16

7

G-CLEVIS TO PEDAL

060701-B0502-05B 1 Stamp T1 Assembly, Mark-up Applied 

@ Bottom. MC-Steel-1018, Bar Cut/Punch/Forming Operator Stamp/Form, XSS 5143 0.5 1 1 0.155 $0.74 $42.73 $24.60 $24.60 $0.11 $0.00 $0.00 $0.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.12 $0.12 $0.11

8

G-FRONT SHELL,PAINTED

060701-B0502-06 1 Paint T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 277 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.03 $0.05 $0.09 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.09 $0.09 $0.00

9 G-FRONT SHELL,WASHED 060701-B0502-06A 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom.

Not Applicable General Assembly Washing Equipment, LMC 277 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.03 $0.08 $0.11 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.11 $0.11 $0.00

10 G-FRONT SHELL,STAMPED 060701-B0502-06B 1 Stamp T1 Assembly, Mark-up Applied 

@ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, LS 493 0.5 1 1 2.283 $0.45 $42.73 $141.76 $141.76 $1.03 $0.04 $0.29 $1.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.36 $1.36 $1.03

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 G-EXCLUDER 060701-B0502-07 1 Mold T2/T3 Inject. Mold, SSLC Thermoset-SBR Mold/Cast/Sinter Operator Inject. Mold, SS 1440 1 1 1 0.049 $1.37 $41.48 $16.39 $16.39 $0.07 $0.03 $0.01 $0.11 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.12 $0.12 $0.07

2 G-VAC HOSE SEAL FRNT SHELL 060701-B0502-08 1 Mold T2/T3 Inject. Mold, SSLC Thermoset-EPDM Mold/Cast/Sinter Operator Inject. Mold, SS 1125 1 1 1 0.011 $1.83 $41.48 $16.39 $16.39 $0.02 $0.04 $0.01 $0.07 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.08 $0.08 $0.02

3 G-VAC HOSE FITTING FRNT SHELL 060701-B0502-09 1 Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 1091 1 1 1 0.013 $1.74 $41.48 $16.39 $16.39 $0.02 $0.04 $0.02 $0.08 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.08 $0.08 $0.02

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

D Purchase Part - Commodity ( Value taken from Purchase Part Database)

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1

 G LABEL, FRONT SHELL, BRAKE 

BOOSTER 060701-B0502-10 1 S $0.00 $0.10 $0.00 $0.10 $0.10

2 G-SPRING LARGE, BRAKE BOOSTER060701-B0502-11 1 S $0.00 $0.45 $0.00 $0.45 $0.45

3 G FOAM SEAL, REAR SHELL 060701-B0502-12 1 S $0.00 $0.10 $0.00 $0.10 $0.10

4 G-FOAM FILTER, LARGE, BOOSTER 060701-B0502-13 1 S $0.00 $0.13 $0.00 $0.13 $0.13

5 G-CLEVIS LOCK NUT, BOOSTER 060701-B0502-14 1 S $0.00 $0.05 $0.00 $0.05 $0.05

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 

Mark-up Calculations.

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly ( Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

7 0 $0.00 $0.00 $0.00 $0.00 $0.00

8 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$2.29

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $2.86

T1 or OEM Total Manufacturing Cost: $2.29 $1.64 $1.18 $5.11 $0.00 $0.02 $0.01 $0.00 $0.03 $5.14

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.03 $0.33 $0.31 $0.13 $0.80

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

3

1

Notes: 

a) Items 1,2, & 3 must a

Base Cost Impact to Vehicle: $2.29 $1.64 $1.18 $5.11 $0.03 $0.35 $0.32 $0.13 $0.82 $5.94 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $5.94

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

G- BRAKE BOOSTER 060701-B0502-02

G-RETAINER, OUTPUT ROD

060701-B0502-04

G-RETAINER, OUTPUT ROD

060701-B0502-04A

G-CLEVIS TO PEDAL

060701-B0502-05

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$1.26 $0.49 $1.75 $0.00 $0.00 $0.00 $0.00 $0.00

Four Operator, four station - Push vacuum seal in place on front shell. Insert vacuum hose fitting and turn 

front shell over. Position large spring into front shell and insert output rod retainer and output rod 

assembly. Insert foam filter into rear shell and put excluder in place. Attach clevis to output shaft with lock 

nut and manually tighten. Apply label

5 2 10 100 47 4700 96 37.60 85% 113 31.96 117.9 14 1 117.9 1.0 4.0

$0.03 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 Wash Rinse & Dry, batch wash 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0

$0.00 $0.00 $0.05 $0.00 $0.00 $0.00 $0.00 $0.00 25 ton progressive die 5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.6 1 1 0.6 1.0 1.0

$0.03 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 Wash Rinse & Dry, batch wash 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

060701-B0502-05

G-CLEVIS TO PEDAL

060701-B0502-05A

G-CLEVIS TO PEDAL

060701-B0502-05B

G-FRONT SHELL,PAINTED

060701-B0502-06

G-FRONT SHELL,WASHED 060701-B0502-06A

G-FRONT SHELL,STAMPED 060701-B0502-06B

Purchase Part - High Impact Item (Full Cost Mapping)

G-EXCLUDER 060701-B0502-07

G-VAC HOSE SEAL FRNT SHELL 060701-B0502-08

G-VAC HOSE FITTING FRNT SHELL 060701-B0502-09

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

$0.03 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 Wash Rinse & Dry, batch wash 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0

$0.09 $0.14 $0.39 $0.00 $0.00 $0.00 $0.00 $0.00 EC-300 5 2 10 100 47 4700 96 37.60 85% 113 31.96 17.0 1 1 17.0 1.0 1.0

$0.00 $0.00 $0.12 $0.00 $0.00 $0.00 $0.00 $0.00 60 ton progressive die 5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.7 1 1 0.7 1.0 1.0

$0.03 $0.05 $0.09 $0.00 $0.00 $0.00 $0.00 $0.00 Spray Paint 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0

$0.03 $0.08 $0.11 $0.00 $0.00 $0.00 $0.00 $0.00 Turbo Tunnel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0

$0.04 $0.29 $1.36 $0.00 $0.00 $0.00 $0.00 $0.00 1000 ton progressive die 5 2 10 100 47 4700 96 37.60 85% 113 31.96 7.3 1 1 7.3 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.03 $0.01 $0.11 $0.00 $0.01 $0.00 $0.00 $0.01 10 Cavity Mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 2.50 1 10 25.00 1.0 1.0

$0.04 $0.01 $0.07 $0.00 $0.00 $0.00 $0.00 $0.01 10 Cavity Mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 3.2 1 10 32 1.0 1.0

$0.04 $0.02 $0.08 $0.00 $0.00 $0.00 $0.00 $0.01 10 Cavity Mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 3.3 1 10 33 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Purchase Part - Commodity ( Value taken from Purchase Part Database)

 G LABEL, FRONT SHELL, BRAKE 

BOOSTER 060701-B0502-10

G-SPRING LARGE, BRAKE BOOSTER060701-B0502-11

G FOAM SEAL, REAR SHELL 060701-B0502-12

G-FOAM FILTER, LARGE, BOOSTER 060701-B0502-13

G-CLEVIS LOCK NUT, BOOSTER 060701-B0502-14

$0.10

$0.45

$0.10

$0.13

$0.05

$0.00

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$1.64 $1.18 $5.11 $0.00 $0.02 $0.01 $0.00 $0.03

$5.14

2

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

G- BRAKE BOOSTER 060701-B0502-02

G-RETAINER, OUTPUT ROD

060701-B0502-04

G-RETAINER, OUTPUT ROD

060701-B0502-04A

G-CLEVIS TO PEDAL

060701-B0502-05

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

122 29.48 4.00

277 13.00 0.25

6000 0.60 0.50

060701-B0502-05 277 13.00 0.25

G-CLEVIS TO PEDAL

060701-B0502-05A

G-CLEVIS TO PEDAL

060701-B0502-05B

G-FRONT SHELL,PAINTED

060701-B0502-06

G-FRONT SHELL,WASHED 060701-B0502-06A

G-FRONT SHELL,STAMPED 060701-B0502-06B

Purchase Part - High Impact Item (Full Cost Mapping)

G-EXCLUDER 060701-B0502-07

G-VAC HOSE SEAL FRNT SHELL 060701-B0502-08

G-VAC HOSE FITTING FRNT SHELL 060701-B0502-09

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

277 13.00 0.25

212 17.00 0.50

5143 0.70 0.50

277 13.00 0.25

277 13.00 0.25

493 7.30 0.50

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

1440 2.50 1.00

1125 3.20 1.00

1091 3.30 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - Commodity ( Value taken from Purchase Part Database)

 G LABEL, FRONT SHELL, BRAKE 

BOOSTER 060701-B0502-10

G-SPRING LARGE, BRAKE BOOSTER060701-B0502-11

G FOAM SEAL, REAR SHELL 060701-B0502-12

G-FOAM FILTER, LARGE, BOOSTER 060701-B0502-13

G-CLEVIS LOCK NUT, BOOSTER 060701-B0502-14

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly(Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 G - OUTPUT ROD ASSEMBLY 060701-B0502-15 1 Assemble T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 150 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.06 $0.10 $0.16 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.16 $0.16 $0.00

4 G-ROD OUTPUT 060701-B0502-16 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LC 277 0.25 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.03 $0.04 $0.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.07 $0.07 $0.00

5 G-ROD OUTPUT 060701-B0502-16A 1 Machine T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable

CNC Operator CNC Machining, LMC, 

Automatic Load 206 1 2 1 0.000 $0.00 $36.98 $46.82 $93.64 $0.00 $0.18 $0.46 $0.63 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.63 $0.63 $0.00

T1 Assembly, Mark-up Applied 

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

6 G-ROD OUTPUT 060701-B0502-16B 1 Forge T1 Assembly, Mark-up Applied 

@ Bottom. MC-Steel-1018, Bar Forging Operator Forge, SS 4000 1 1 1 0.105 $0.74 $40.18 $115.72 $115.72 $0.08 $0.01 $0.03 $0.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.12 $0.12 $0.08

7

G-SOCKET, OUTPUT ROD

060701-B0502-17 1 Batch Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LC 277 0.25 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.03 $0.04 $0.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.07 $0.07 $0.00

8

G-SOCKET, OUTPUT ROD

060701-B0502-17A 1 Pre cut bar, machined T1 Assembly, Mark-up Applied 

@ Bottom. HC-Steel-1040S, Bar CNC Operator DS-CNC Turning, SMS, BF, DA 138 0.5 1 1 0.020 $0.80 $36.98 $27.76 $27.76 $0.02 $0.13 $0.20 $0.35 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.35 $0.35 $0.02

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

D Purchase Part - Commodity ( Value taken from Purchase Part Database)

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 0 $0.00 $0.00 $0.00 $0.00 $0.00

2 G WASHER, OUTPUT ROD, 1.00 MM 060701-B0502-18 1 S $0.00 $0.01 $0.00 $0.01 $0.01

3 0 $0.00 $0.00 $0.00 $0.00 $0.00

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

5 0 $0.00 $0.00 $0.00 $0.00 $0.00

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

7 0 $0.00 $0.00 $0.00 $0.00

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 

Mark-up Calculations.

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly(Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Material

$0.10

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $0.17

T1 or OEM Total Manufacturing Cost: $0.10 $0.46 $0.86 $1.42 $0.00 $0.00 $0.00 $0.00 $0.00 $1.42

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.09 $0.09 $0.04 $0.22

Base Cost Impact to Vehicle: $0.10 $0.46 $0.86 $1.42 $0.01 $0.09 $0.09 $0.04 $0.22 $1.64 $0 $0

Packaging Cost: $0.00

3

1

Notes: 

a) Items 1,2, & 3 must a

Net Cost Impact to Vehicle: $1.64

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

G - OUTPUT ROD ASSEMBLY 060701-B0502-15

G-ROD OUTPUT 060701-B0502-16

G-ROD OUTPUT 060701-B0502-16A

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.06 $0.10 $0.16 $0.00 $0.00 $0.00 $0.00 $0.00 Press Socket, Output rod, washer together 5 2 10 100 47 4700 96 37.60 85% 113 31.96 24 1 1 24 1.0 1.0

$0.03 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 Wash Rinse & Dry, batch wash 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0

$0.18 $0.46 $0.63 $0.00 $0.00 $0.00 $0.00 $0.00 CNC Turning, 2 axis, SL-10 5 2 10 100 47 4700 96 37.60 85% 113 31.96 35 6 1 35 1.0 2.0

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

G-ROD OUTPUT 060701-B0502-16B

G-SOCKET, OUTPUT ROD

060701-B0502-17

G-SOCKET, OUTPUT ROD

060701-B0502-17A

Purchase Part - High Impact Item (Full Cost Mapping)

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

$0.01 $0.03 $0.12 $0.00 $0.00 $0.00 $0.00 $0.00 500 Ton 5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.9 1 1 0.9 1.0 1.0

$0.03 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 Wash Rinse & Dry, batch wash 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0

$0.13 $0.20 $0.35 $0.00 $0.00 $0.00 $0.00 $0.00 TL-15 Turning , 4 axis, Twin Spindle 5 2 10 100 47 4700 96 37.60 85% 113 31.96 26 6 1 26 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Purchase Part - Commodity ( Value taken from Purchase Part Database)

G WASHER, OUTPUT ROD, 1.00 MM 060701-B0502-18

$0.00

$0.01

$0.00

$0.00

$0.00

$0.00

$0.00

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$0.46 $0.86 $1.42 $0.00 $0.00 $0.00 $0.00 $0.00

$1.42

2

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

G - OUTPUT ROD ASSEMBLY 060701-B0502-15

G-ROD OUTPUT 060701-B0502-16

G-ROD OUTPUT 060701-B0502-16A

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

150 24.00 0.25

277 13.00 0.25

206 17.50 1.00

G-ROD OUTPUT 060701-B0502-16B

G-SOCKET, OUTPUT ROD

060701-B0502-17

G-SOCKET, OUTPUT ROD

060701-B0502-17A

Purchase Part - High Impact Item (Full Cost Mapping)

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

4000 0.90 1.00

277 13.00 0.25

138 26.00 0.50

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - Commodity ( Value taken from Purchase Part Database)

G WASHER, OUTPUT ROD, 1.00 MM 060701-B0502-18

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly(Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 G-REAR ASSEMBLY 060701-B0502-19 1 Assemble T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 148 4 4 1 0.000 $0.00 $38.55 $15.00 $60.00 $0.00 $1.04 $0.40 $1.44 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.44 $1.44 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 G - VACUUM SEAL, REAR SHELL 060701-B0502-20 1 Mold T2/T3 Inject. Mold, SSLC TPE-PP/EPDM, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 1500 1 1 1 0.0190 $0.99 $41.48 $16.39 $16.39 $0.02 $0.03 $0.01 $0.06 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.06 $0.06 $0.02

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

D Purchase Part - Commodity ( Value taken from Purchase Part Database)

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 0 $0.00 $0.00 $0.00 $0.00 $0.00

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

5 0 $0.00 $0.00 $0.00 $0.00 $0.00

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

6 0 "SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.02

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $1.51

T1 or OEM Total Manufacturing Cost: $0.02 $1.07 $0.42 $1.50 $0.00 $0.00 $0.00 $0.00 $0.01 $1.51

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.10 $0.09 $0.04 $0.23

Base Cost Impact to Vehicle: $0.02 $1.07 $0.42 $1.50 $0.01 $0.10 $0.09 $0.04 $0.24 $1.74 $0 $0

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

3

1

Notes: 

a) Items 1,2, & 3 must a

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly(Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $1.74

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Cost per Pallet /Rack

Total Number of Pallets/

Number of Parts per Pallet/Supplier, Customer and InRequirements (Weeks)Supplier, Customer and InRequirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

G-REAR ASSEMBLY 060701-B0502-19

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$1.04 $0.40 $1.44 $0.00 $0.00 $0.00 $0.00 $0.00 Four operator, four station. Grease and insert vacuum seal into rear shell. Insert center plate assembly and 

tie rods.Manually screw tie rod nuts in place 5 2 10 100 47 4700 96 37.60 85% 113 31.96 97 7 1 97 1.0 4.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Purchase Part - High Impact Item (Full Cost Mapping)

G - VACUUM SEAL, REAR SHELL 060701-B0502-20

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Purchase Part - Commodity ( Value taken from Purchase Part Database)

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.03 $0.01 $0.06 $0.00 $0.00 $0.00 $0.00 $0.01 10 Cavity Mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 2.40 1 10 24.00 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00

$0.00

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$1.07 $0.42 $1.50 $0.00 $0.00 $0.00 $0.00 $0.01

$1.51

2

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

G-REAR ASSEMBLY 060701-B0502-19

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

148 24.25 4.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

G - VACUUM SEAL, REAR SHELL 060701-B0502-20

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Purchase Part - Commodity ( Value taken from Purchase Part Database)

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

1500 2.40 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly(Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 0.5 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4

G-SHELL REAR,PAINTED

060701-B0502-21 1 Paint T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 277 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.03 $0.05 $0.09 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.09 $0.09 $0.00

5

G-SHELL REAR,PRESSED

060701-B0502-21A 1 Press T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 189 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.05 $0.08 $0.13 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.13 $0.13 $0.00

6 G-SHELL REAR,WASHED 060701-B0502-21B 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom.

Not Applicable General Assembly Washing Equipment, LMC 277 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.03 $0.08 $0.11 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.11 $0.11 $0.00

7 G-SHELL REAR ,STAMPED 060701-B0502-21C 1 Stamp T1 Assembly, Mark-up Applied LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, LS 493 0.5 1 1 1.524 $0.45 $42.73 $141.76 $141.76 $0.69 $0.04 $0.29 $1.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.02 $1.02 $0.69

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

7 G-SHELL REAR ,STAMPED 060701-B0502-21C 1 Stamp T1 Assembly, Mark-up Applied 

@ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, LS 493 0.5 1 1 1.524 $0.45 $42.73 $141.76 $141.76 $0.69 $0.04 $0.29 $1.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.02 $1.02 $0.69

8

 G-SHELL REAR STUD PLATE, BOOSTER, 

WASHED 060701-B0502-22 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LMC 277 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.03 $0.08 $0.11 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.11 $0.11 $0.00

8

 G-SHELL REAR STUD PLATE, BOOSTER, 

STAMPED 060701-B0502-22A 1 Stamp T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator

Stamp/Form, Terminals

1565 0.5 1 1 0.442 $0.45 $42.73 $15.50 $15.50 $0.20 $0.01 $0.01 $0.22 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.22 $0.22 $0.20

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

Purchase Part - Commodity ( Value taken from Purchase Part Database)

Supplier Purchase Purchase Purchase 

D Purchase Part - Commodity ( Value taken from Purchase Part Database)

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 0 $0.00 $0.00 $0.00 $0.00 $0.00

2 G-STUD, REAR SHELL 060701-B0502-23 2 S $0.00 $0.04 $0.00 $0.08 $0.08

3 0 $0.00 $0.00 $0.00 $0.00 $0.00

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.96

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly(Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $1.76

T1 or OEM Total Manufacturing Cost: $0.96 $0.21 $0.58 $1.76 $0.00 $0.00 $0.00 $0.00 $0.00 $1.76

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.11 $0.11 $0.04 $0.27

Base Cost Impact to Vehicle: $0.96 $0.21 $0.58 $1.76 $0.01 $0.11 $0.11 $0.04 $0.27 $2.03 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $2.03

3

1

Notes: 

a) Items 1,2, & 3 must a

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

G-SHELL REAR,PAINTED

060701-B0502-21

G-SHELL REAR,PRESSED

060701-B0502-21A

G-SHELL REAR,WASHED 060701-B0502-21B

G-SHELL REAR ,STAMPED 060701-B0502-21C

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 1 1 10 10 47 470 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 0.5

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.03 $0.05 $0.09 $0.00 $0.00 $0.00 $0.00 $0.00 Spray Paint 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0

$0.05 $0.08 $0.13 $0.00 $0.00 $0.00 $0.00 $0.00 Press Rear Shell and studs together 5 2 10 100 47 4700 96 37.60 85% 113 31.96 19 1 1 19 1.0 1.0

$0.03 $0.08 $0.11 $0.00 $0.00 $0.00 $0.00 $0.00 Turbo Tunnel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0

$0.04 $0.29 $1.02 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 96 37.60 85% 113 31.96 7.3 1 1 7.3 1.0 1.0

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

G-SHELL REAR ,STAMPED 060701-B0502-21C

 G-SHELL REAR STUD PLATE, BOOSTER, 

WASHED 060701-B0502-22

 G-SHELL REAR STUD PLATE, BOOSTER, 

STAMPED 060701-B0502-22A

Purchase Part - High Impact Item (Full Cost Mapping)

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Purchase Part - Commodity ( Value taken from Purchase Part Database)

$0.04 $0.29 $1.02 $0.00 $0.00 $0.00 $0.00 $0.00 1000 ton progressive die 5 2 10 100 47 4700 96 37.60 85% 113 31.96 7.3 1 1 7.3 1.0 1.0

$0.03 $0.08 $0.11 $0.00 $0.00 $0.00 $0.00 $0.00 Turbo Tunnel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0

$0.01 $0.01 $0.22 $0.00 $0.00 $0.00 $0.00 $0.00 60 ton progressive die 5 2 10 100 47 4700 96 37.60 85% 113 31.96 2.3 1 1 2.3 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Purchase Part - Commodity ( Value taken from Purchase Part Database)

G-STUD, REAR SHELL 060701-B0502-23

$0.00

$0.08

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$0.21 $0.58 $1.76 $0.00 $0.00 $0.00 $0.00 $0.00

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

$1.76

2

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

G-SHELL REAR,PAINTED

060701-B0502-21

G-SHELL REAR,PRESSED

060701-B0502-21A

G-SHELL REAR,WASHED 060701-B0502-21B

G-SHELL REAR ,STAMPED 060701-B0502-21C

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0!

#DIV/0! #DIV/0! -

277 13.00 0.25

189 19.00 0.25

277 13.00 0.25

G-SHELL REAR ,STAMPED 060701-B0502-21C 493 7.30 0.50

 G-SHELL REAR STUD PLATE, BOOSTER, 

WASHED 060701-B0502-22

 G-SHELL REAR STUD PLATE, BOOSTER, 

STAMPED 060701-B0502-22A

Purchase Part - High Impact Item (Full Cost Mapping)

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Purchase Part - Commodity ( Value taken from Purchase Part Database)

493 7.30 0.50

277 13.00 0.25

1565 2.30 0.50

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - Commodity ( Value taken from Purchase Part Database)

G-STUD, REAR SHELL 060701-B0502-23

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly(Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 G-CENTER PLATE ASSEMBLY, BOOSTER 060701-B0502-24 1 Assemble T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 240 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.04 $0.06 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

D Purchase Part - Commodity ( Value taken from Purchase Part Database)

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 0 $0.00 $0.00 $0.00 $0.00 $0.00

4 G-TIE ROD, BRAKE BOOSTER 060701-B0502-25 2 S $0.00 $0.335 $0.00 $0.67 $0.67

5 G-O-RING, TIE ROD, BOOSTER 060701-B0502-26 2 S $0.00 $0.055 $0.00 $0.11 $0.11

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

Material

$0.78

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $0.88

T1 or OEM Total Manufacturing Cost: $0.78 $0.04 $0.06 $0.88 $0.00 $0.00 $0.00 $0.00 $0.00 $0.88

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.06 $0.05 $0.02 $0.14

Base Cost Impact to Vehicle: $0.78 $0.04 $0.06 $0.88 $0.00 $0.06 $0.05 $0.02 $0.14 $1.02 $0 $0

Packaging Cost: $0.00

3

1

Notes: 

a) Items 1,2, & 3 must a

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly(Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Net Cost Impact to Vehicle: $1.02

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization:

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

G-CENTER PLATE ASSEMBLY, BOOSTER 060701-B0502-24

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.04 $0.06 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Lube and set o-ring in place 5 2 10 100 47 4700 96 37.60 85% 113 31.96 15 2 1 15 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

Purchase Part - High Impact Item (Full Cost Mapping)

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Purchase Part - Commodity ( Value taken from Purchase Part Database)

G-TIE ROD, BRAKE BOOSTER 060701-B0502-25

G-O-RING, TIE ROD, BOOSTER 060701-B0502-26

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 10 Cavity Mold 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 60 ton progressive die 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00

$0.67

$0.11

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$0.04 $0.06 $0.88 $0.00 $0.00 $0.00 $0.00 $0.00

$0.88

2

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

G-CENTER PLATE ASSEMBLY, BOOSTER 060701-B0502-24

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

240 15.00 0.25

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Purchase Part - Commodity ( Value taken from Purchase Part Database)

G-TIE ROD, BRAKE BOOSTER 060701-B0502-25

G-O-RING, TIE ROD, BOOSTER 060701-B0502-26

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly(Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 G-CENTER PLATE ASSEMBLY, BOOSTER 060701-B0502-27 1 Assemble T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 225 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.04 $0.07 $0.11 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.11 $0.11 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

D Purchase Part - Commodity ( Value taken from Purchase Part Database)

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 0 $0.00 $0.00 $0.00 $0.00 $0.00

4 G-NUT, TIE ROD ADJUSTER 060701-B0502-28 2 S $0.00 $0.065 $0.00 $0.13 $0.13

5 G-O-RING, TIE ROD, BOOSTER 060701-B0502-29 2 S $0.00 $0.055 $0.00 $0.11 $0.11

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

$0.24

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $0.35

T1 or OEM Total Manufacturing Cost: $0.24 $0.04 $0.07 $0.35 $0.00 $0.00 $0.00 $0.00 $0.00 $0.35

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.02 $0.02 $0.01 $0.05

Base Cost Impact to Vehicle: $0.24 $0.04 $0.07 $0.35 $0.00 $0.02 $0.02 $0.01 $0.05 $0.40 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $0.40

3

1

Notes: 

a) Items 1,2, & 3 must a

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly(Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

G-CENTER PLATE ASSEMBLY, BOOSTER 060701-B0502-27

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.04 $0.07 $0.11 $0.00 $0.00 $0.00 $0.00 $0.00 Lube and set o-ring in place 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 2 1 16 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Purchase Part - High Impact Item (Full Cost Mapping)

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Purchase Part - Commodity ( Value taken from Purchase Part Database)

G-NUT, TIE ROD ADJUSTER 060701-B0502-28

G-O-RING, TIE ROD, BOOSTER 060701-B0502-29

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 10 Cavity Mold 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 60 ton progressive die 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00

$0.13

$0.11

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total Labor Burden TMC Scrape SG&A Profit ED&T Total

$0.04 $0.07 $0.35 $0.00 $0.00 $0.00 $0.00 $0.00

$0.35

2

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

G-CENTER PLATE ASSEMBLY, BOOSTER 060701-B0502-27

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

225 16.00 0.25

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Purchase Part - Commodity ( Value taken from Purchase Part Database)

G-NUT, TIE ROD ADJUSTER 060701-B0502-28

G-O-RING, TIE ROD, BOOSTER 060701-B0502-29

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly(Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 G-CENTER PLATE ASSEMBLY, BOOSTER 060701-B0502-30 1 Assemble T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 113 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.69 $0.27 $0.95 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.95 $0.95 $0.00

2 G-CENTER PLATE 060701-B0502-30A 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. LC-Steel-1000S, Coil General Assembly Washing Equipment, LMC 277 0.25 1 1 0.000 $0.45 $38.55 $20.81 $20.81 $0.00 $0.03 $0.08 $0.11 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.11 $0.11 $0.00

3 G-CENTER PLATE 060701-B0502-30B 1 Stamp T1 Assembly, Mark-up Applied 

@ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator

Stamp/Form, SS

2118 0.5 1 1 1.378 $0.45 $42.73 $42.91 $42.91 $0.62 $0.01 $0.02 $0.65 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.65 $0.65 $0.62

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 G - DIAPHRAGM, CENTER PLATE 060701-B0502-31 1 Mold T2/T3 Inject. Mold, SSLC Thermoset-SBR Mold/Cast/Sinter Operator Inject. Mold, MLS 837 1 1 1 0.232 $1.32 $41.48 $90.59 $90.59 $0.31 $0.05 $0.11 $0.46 0.30% 6.00% 4.00% 0.00% 10.30% $0.05 $0.51 $0.51 $0.31

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

D Purchase Part - Commodity ( Value taken from Purchase Part Database)

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 0 $0.00 $0.00 $0.00 $0.00 $0.00

2 0 $0.00 $0.00 $0.00 $0.00 $0.00

3 0 $0.00 $0.00 $0.00 $0.00 $0.00

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.93

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $1.27

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

1

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly(Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

T1 or OEM Total Manufacturing Cost: $0.93 $0.78 $0.47 $2.18 $0.00 $0.03 $0.02 $0.00 $0.05 $2.22

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.14 $0.13 $0.06 $0.34

Base Cost Impact to Vehicle: $0.93 $0.78 $0.47 $2.18 $0.01 $0.17 $0.15 $0.06 $0.39 $2.57 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $2.57

Total Number of Pallets/

Number of Parts per Pallet/Supplier, Customer and InRequirements (Weeks)Supplier, Customer and InPACKAGING CALCULATIONS: 

3

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

G-CENTER PLATE ASSEMBLY, BOOSTER 060701-B0502-30

G-CENTER PLATE 060701-B0502-30A

G-CENTER PLATE 060701-B0502-30B

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.69 $0.27 $0.95 $0.00 $0.00 $0.00 $0.00 $0.00 Two operator, two station. Insert diaphragm and valve body assembly into greased center plate and crimp 5 2 10 100 47 4700 96 37.60 85% 113 31.96 64 3 1 64 1.0 2.0

$0.03 $0.08 $0.11 $0.00 $0.00 $0.00 $0.00 $0.00

In line Washer Turbo Tunnel

5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0

$0.01 $0.02 $0.65 $0.00 $0.00 $0.00 $0.00 $0.00 200 ton progressive die 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1.7 1 1 1.7 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Purchase Part - High Impact Item (Full Cost Mapping)

G - DIAPHRAGM, CENTER PLATE 060701-B0502-31

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Purchase Part - Commodity ( Value taken from Purchase Part Database)

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.05 $0.11 $0.46 $0.00 $0.03 $0.02 $0.00 $0.05 4 Cavity Mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 4.30 1 4 17.20 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00

$0.00

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$0.78 $0.47 $2.18 $0.00 $0.03 $0.02 $0.00 $0.05

$2.22

2

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

G-CENTER PLATE ASSEMBLY, BOOSTER 060701-B0502-30

G-CENTER PLATE 060701-B0502-30A

G-CENTER PLATE 060701-B0502-30B

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

113 32.00 2.00

277 13.00 0.25

2118 1.70 0.50

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

G - DIAPHRAGM, CENTER PLATE 060701-B0502-31

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Purchase Part - Commodity ( Value taken from Purchase Part Database)

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

837 4.30 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly(Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

1 G-VALVE BODY ASSEMBLY, BODY 060701-B0502-32 1 Assemble T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 122 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.63 $0.25 $0.88 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.88 $0.88 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 G-VALVE BODY,MOLDED 060701-B0502-33 1 Mold T2/T3 Inject. Mold, SSLC PET-GF36 Mold/Cast/Sinter Operator Inject. Mold, MLS 886 1 1 1 0.209 $1.20 $41.48 $90.59 $90.59 $0.25 $0.05 $0.10 $0.40 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.44 $0.44 $0.25

2 G-REACTION DISK 060701-B0502-34 1 Mold T2/T3 Inject. Mold, SSLC Thermoset-SBR Mold/Cast/Sinter Operator Inject. Mold, SS 450 1 1 1 0.010 $1.32 $41.48 $16.39 $16.39 $0.01 $0.09 $0.04 $0.14 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.16 $0.16 $0.01

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

D Purchase Part - Commodity ( Value taken from Purchase Part Database)

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 GREEN FOAM FILTER VALVE BODY 060701-B0502-35 1 S $0.00 $0.06 $0.00 $0.06 $0.06

2

 G-FOAM FILTER, YELLOW, VALVE 

BODY, 060701-B0502-36 1 S $0.00 $0.05 $0.00 $0.05 $0.05

3 0 $0.00 $0.00 $0.00 $0.00 $0.00

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

$0.37

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $1.58

T1 or OEM Total Manufacturing Cost: $0.37 $0.77 $0.38 $1.53 $0.00 $0.03 $0.02 $0.00 $0.06 $1.58

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.10 $0.10 $0.04 $0.25

Base Cost Impact to Vehicle: $0.37 $0.77 $0.38 $1.53 $0.01 $0.14 $0.12 $0.04 $0.30 $1.83 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $1.83

3

1

Notes: 

a) Items 1,2, & 3 must a

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly(Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

G-VALVE BODY ASSEMBLY, BODY 060701-B0502-32

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.63 $0.25 $0.88 $0.00 $0.00 $0.00 $0.00 $0.00 Two operator, Two station. Insert input rod assembly and reaction disk into the body, valve booster. Apply 

grease to shaft and slip on yellow and green foam filters. Secure with key, booster. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 59 5 1 59 1.0 2.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

Purchase Part - High Impact Item (Full Cost Mapping)

G-VALVE BODY,MOLDED 060701-B0502-33

G-REACTION DISK 060701-B0502-34

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Purchase Part - Commodity ( Value taken from Purchase Part Database)

GREEN FOAM FILTER VALVE BODY 060701-B0502-35

 G-FOAM FILTER, YELLOW, VALVE 

BODY, 060701-B0502-36

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.05 $0.10 $0.40 $0.00 $0.02 $0.02 $0.00 $0.04 4 Cavity Mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 4.1 1 4 16.24 1.0 1.0

$0.09 $0.04 $0.14 $0.00 $0.01 $0.01 $0.00 $0.01 10 Cavity Mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 8 1 10 80 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.06

$0.05

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$0.77 $0.38 $1.53 $0.00 $0.03 $0.02 $0.00 $0.06

$1.58

2

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

G-VALVE BODY ASSEMBLY, BODY 060701-B0502-32

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

122 29.50 2.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

G-VALVE BODY,MOLDED 060701-B0502-33

G-REACTION DISK 060701-B0502-34

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Purchase Part - Commodity ( Value taken from Purchase Part Database)

GREEN FOAM FILTER VALVE BODY 060701-B0502-35

 G-FOAM FILTER, YELLOW, VALVE 

BODY, 060701-B0502-36

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

886 4.06 1.00

450 8.00 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly(Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 G-INPUT ROD ASSEMBLY 060701-B0502-37 1 Assemble T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 131 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.59 $0.23 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82 $0.00

4

G-INPUT ROD, VALVE BODY

060701-B0502-37A 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LC 277 0.25 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.03 $0.04 $0.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.07 $0.07 $0.00

5

G-INPUT ROD, VALVE BODY

060701-B0502-37B 1 Machine T1 Assembly, Mark-up Applied 

@ Bottom. MC-Steel-1018, Bar CNC Operator CNC Turning, SS, BF, DA 195 1 2 1 0.150 $0.74 $36.98 $20.48 $40.96 $0.11 $0.19 $0.21 $0.51 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.51 $0.51 $0.11

6 060701-B0502-38 1 Wash T1 Assembly, Mark-up Applied Not Applicable General Assembly Washing Equipment, LC 300 0.25 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.03 $0.04 $0.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.07 $0.07 $0.00

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

6

G-PLUNGER, VALVE BODY

060701-B0502-38 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LC 300 0.25 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.03 $0.04 $0.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.07 $0.07 $0.00

7

G-PLUNGER, VALVE BODY

060701-B0502-38A 1 Machine T1 Assembly, Mark-up Applied 

@ Bottom. MC-Steel-1018, Bar CNC Operator CNC Turning, SS, BF, DA 153 1 2 1 0.220 $0.74 $36.98 $20.48 $40.96 $0.16 $0.24 $0.27 $0.67 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.67 $0.67 $0.16

8

G-RETAINER INPUT ROD SPRING

060701-B0502-38B 1 Stamp T1 Assembly, Mark-up Applied 

@ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator

Stamp/Form, XSS

2000 0.5 1 1 0.016 $0.45 $42.73 $24.60 $24.60 $0.01 $0.01 $0.01 $0.03 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.03 $0.03 $0.01

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 G-POPPET VALVE BODY 060701-B0502-39 1 Mold T2/T3 Inject. Mold, SSLC Thermoset-SBR Mold/Cast/Sinter Operator Inject. Mold, SS 720 1 1 1 0.020 $1.32 $41.48 $16.39 $16.39 $0.03 $0.06 $0.02 $0.11 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.12 $0.12 $0.03

2 G-RETAINER POPPET SPRING 060701-B0502-40 1 Mold T2/T3 Inject. Mold, SSLC PET-GF36 Mold/Cast/Sinter Operator Inject. Mold, SS 4000 1 1 1 0.021 $1.20 $41.48 $16.39 $16.39 $0.03 $0.01 $0.00 $0.04 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.04 $0.04 $0.03

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

D Purchase Part - Commodity ( Value taken from Purchase Part Database)

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 G-SPRING, INPUT ROD 060701-B0502-41 1 S $0.00 $0.07 $0.00 $0.07 $0.07

2 G- SPRING, POPPET VALVE 060701-B0502-42 1 S $0.00 $0.04 $0.00 $0.04 $0.04

3 G-WASHER, POPPET VALVE BODY 060701-B0502-43 1 S $0.00 $0.02 $0.00 $0.02 $0.02

4 G-SEAL, POPPET VALVE 060701-B0502-44 1 S $0.00 $0.06 $0.00 $0.06 $0.06

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

4 G-SEAL, POPPET VALVE 060701-B0502-44 1 S "SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to $0.00 $0.06 $0.00 $0.06 $0.06

Material

$0.52

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $91.35

T1 or OEM Total Manufacturing Cost: $0.52 $1.17 $0.82 $2.51 $0.00 $0.01 $0.01 $0.00 $0.02 $2.52

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.16 $0.15 $0.06 $0.39

Base Cost Impact to Vehicle: $0.52 $1.17 $0.82 $2.51 $0.01 $0.17 $0.16 $0.06 $0.41 $2.92 $0 $0

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

3

1

Notes: 

a) Items 1,2, & 3 must a

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly(Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $2.92

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Cost per Pallet /Rack

Total Number of Pallets/

Number of Parts per Pallet/Supplier, Customer and InRequirements (Weeks)Supplier, Customer and InRequirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

G-INPUT ROD ASSEMBLY 060701-B0502-37

G-INPUT ROD, VALVE BODY

060701-B0502-37A

G-INPUT ROD, VALVE BODY

060701-B0502-37B

060701-B0502-38

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.59 $0.23 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00

Two Operator, two station. Attach plunger rod to body. Apply seal to greased poppet valve retainer. Place 

plunger spring in retainer, place valve body on top and insert plunger/body asm and compress. Apply 

metal retainer and slip on poppet valve spring.

5 2 10 100 47 4700 96 37.60 85% 113 31.96 55 6 1 55 1.0 2.0

$0.03 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00 $0.00

Batch Wash

5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0

$0.19 $0.21 $0.51 $0.00 $0.00 $0.00 $0.00 $0.00 SL-10 turning 1.75" Bar, 2 axis 5 2 10 100 47 4700 96 37.60 85% 113 31.96 37 4 1 37 1.0 2.0

$0.03 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 96 37.60 85% 113 31.96 12 1 1 12 1.0 1.0

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

G-PLUNGER, VALVE BODY

060701-B0502-38

G-PLUNGER, VALVE BODY

060701-B0502-38A

G-RETAINER INPUT ROD SPRING

060701-B0502-38B

Purchase Part - High Impact Item (Full Cost Mapping)

G-POPPET VALVE BODY 060701-B0502-39

G-RETAINER POPPET SPRING 060701-B0502-40

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Purchase Part - Commodity ( Value taken from Purchase Part Database)

G-SPRING, INPUT ROD 060701-B0502-41

G- SPRING, POPPET VALVE 060701-B0502-42

G-WASHER, POPPET VALVE BODY 060701-B0502-43

G-SEAL, POPPET VALVE 060701-B0502-44

$0.03 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00 $0.00

Batch Wash

5 2 10 100 47 4700 96 37.60 85% 113 31.96 12 1 1 12 1.0 1.0

$0.24 $0.27 $0.67 $0.00 $0.00 $0.00 $0.00 $0.00 SL-10 turning 1.75" Bar, 2 axis 5 2 10 100 47 4700 96 37.60 85% 113 31.96 47 6 1 47 1.0 2.0

$0.01 $0.01 $0.03 $0.00 $0.00 $0.00 $0.00 $0.00 25 ton progressive die 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1.8 1 1 1.8 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.06 $0.02 $0.11 $0.00 $0.01 $0.00 $0.00 $0.01 8 Cavity Mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 5 1 8 40 1.0 1.0

$0.01 $0.00 $0.04 $0.00 $0.00 $0.00 $0.00 $0.00 10 Cavity Mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.9 1 10 9 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.07

$0.04

$0.02

G-SEAL, POPPET VALVE 060701-B0502-44 $0.06

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$1.17 $0.82 $2.51 $0.00 $0.01 $0.01 $0.00 $0.02

$2.52

2

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

G-INPUT ROD ASSEMBLY 060701-B0502-37

G-INPUT ROD, VALVE BODY

060701-B0502-37A

G-INPUT ROD, VALVE BODY

060701-B0502-37B

060701-B0502-38

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

131 27.50 2.00

277 13.00 0.25

195 18.50 1.00

300 12.00 0.25

G-PLUNGER, VALVE BODY

060701-B0502-38

G-PLUNGER, VALVE BODY

060701-B0502-38A

G-RETAINER INPUT ROD SPRING

060701-B0502-38B

Purchase Part - High Impact Item (Full Cost Mapping)

G-POPPET VALVE BODY 060701-B0502-39

G-RETAINER POPPET SPRING 060701-B0502-40

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Purchase Part - Commodity ( Value taken from Purchase Part Database)

G-SPRING, INPUT ROD 060701-B0502-41

G- SPRING, POPPET VALVE 060701-B0502-42

G-WASHER, POPPET VALVE BODY 060701-B0502-43

G-SEAL, POPPET VALVE 060701-B0502-44

300 12.00 0.25

153 23.50 1.00

2000 1.80 0.50

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

720 5.00 1.00

4000 0.90 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

G-SEAL, POPPET VALVE 060701-B0502-44

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly(Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 G-KEY BOOSTER, MATE 060701-B0502-45 1 Mold T2/T3 Inject. Mold, SSLC Thermoset-EPDM Mold/Cast/Sinter Operator Inject. Mold, SS 750 1 1 1 0.006 $1.83 $41.48 $16.39 $16.39 $0.01 $0.06 $0.02 $0.09 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.10 $0.10 $0.01

2 G-KEY, BOOSTER, METAL 060701-B0502-46 1 Stamp T2/T3 Stamp/Form, MSMC HC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals 5143 0.5 1 1 0.103 $0.65 $42.73 $15.50 $15.50 $0.07 $0.00 $0.00 $0.07 0.50% 6.50% 6.00% 1.00% 14.00% $0.01 $0.08 $0.08 $0.07

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

D Purchase Part - Commodity ( Value taken from Purchase Part Database)

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 0 $0.00 $0.00 $0.00 $0.00 $0.00

2 0 $0.00 $0.00 $0.00 $0.00 $0.00

3 0 $0.00 $0.00 $0.00 $0.00 $0.00

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

$0.08

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $0.18

T1 or OEM Total Manufacturing Cost: $0.08 $0.06 $0.02 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02 $0.18

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.01 $0.01 $0.00 $0.03

Base Cost Impact to Vehicle: $0.08 $0.06 $0.02 $0.16 $0.00 $0.02 $0.02 $0.01 $0.05 $0.21 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $0.21

3

1

Notes: 

a) Items 1,2, & 3 must a

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: G Brake Booster Assembly(Master Cylinder Removed) Part Number: 060701-B0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

Parallel Hybrid

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

Purchase Part - High Impact Item (Full Cost Mapping)

G-KEY BOOSTER, MATE 060701-B0502-45

G-KEY, BOOSTER, METAL 060701-B0502-46

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Purchase Part - Commodity ( Value taken from Purchase Part Database)

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.06 $0.02 $0.09 $0.00 $0.01 $0.00 $0.00 $0.01 10 Cavity Mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 4.8 1 10 48 1.0 1.0

$0.00 $0.00 $0.07 $0.00 $0.00 $0.00 $0.00 $0.01 60 ton progressive die 5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.7 1 1 0.7 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00

$0.00

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total Labor Burden TMC Scrape SG&A Profit ED&T Total

$0.06 $0.02 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02

$0.18

2

Notes: 

a) Items 1,2, & 3 must all equal same value otherwise there is a computation error.

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

G-KEY BOOSTER, MATE 060701-B0502-45

G-KEY, BOOSTER, METAL 060701-B0502-46

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Purchase Part - Commodity ( Value taken from Purchase Part Database)

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

750 4.80 1.00

5143 0.70 0.50

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Indented Bill of Materials

G Brake Booster Assembly

Level Symbol Name Number

G BRAKE BOOSTER G BRAKE BOOSTER

1 G FRONT SHELL, BRAKE BOOSTER G FRONT SHELL, BRAKE BOOSTER

2 G-FRONT SHELL - Wash G-FRONT SHELL -Wash

3 G-FRONT SHELL - Stamping G-FRONT SHELL -Stamping

4 G-REAR SHELL -Material G-REAR SHELL -Material

1 G-VAC HOSE SEAL FRNT SHELL G Vacuum Hose Seal, Front Shell

2 G-VAC HOSE SEAL FRNT SHELL -Material H Vacuum Hose Seal, Front Shell, Material

1 G-VAC HOSE FITTING FRNT SHELL G-VAC HOSE FITTING FRNT SHELL

2 G-VAC HOSE FITTING FRNT SHELL, MATERIAL G-VAC HOSE FITTING FRNT SHELL, MATERIAL

1 G-SPRING LARGE, BRAKE BOOSTER G-SPRING LARGE, BRAKE BOOSTER

1 G-RETAINER, OUTPUT ROD G-RETAINER, OUTPUT ROD

2 G-RETAINER, OUTPUT ROD, STAMPED G-RETAINER, OUTPUT ROD, STAMPED

3 G-RETAINER, OUTPUT ROD,MATERIAL G-RETAINER, OUTPUT ROD,MATERIAL

1 G OUTPUT ROD ASM G OUTPUT ROD ASM

2 G Rod Output G Rod Output

3 G Rod Output, Machined G Rod Output, Machined

4 G Output Rod, Forged G Output Rod, Forged

5 G Output Rod, Material G Output Rod, Material

2 G Washer, Output Rod, 1.00 mm G Washer, Output Rod, 1.00 mm

2 G Socket, Output Rod G Socket, Output Rod

3 G Socket, Output Rod, Machined G Socket, Output Rod, Machined

4 G Socket, Output Rod, Material G Socket, Output Rod, Material

1 G-REAR ASSEMBLY SSEMBLY G-REAR ASSEMBLY SSEMBLY

2 G SHELL REAR W/STUDS G SHELL REAR W/STUDS

3 G SHELL REAR W/STUDS-Press G SHELL REAR W/STUDS-Press

4 G-SHELL REAR BOOSTER G-SHELL REAR BOOSTER

5 G-SHELL REAR BOOSTER, STAMPED G-SHELL REAR BOOSTER, STAMPED

6 G SHELL REAR-Material G SHELL REAR-Material

4 G SHELL REAR STUD PLATE G SHELL REAR STUD PLATE

5 G SHELL REAR STUD PLATE-Stamped G SHELL REAR STUD PLATE-Wash

6 G SHELL REAR STUD PLATE-Material G SHELL REAR STUD PLATE-Material

4 G STUD, REAR SHELL G STUD, REAR SHELL

2 G-VACUUM SEAL REAR SHELL G-VACUUM SEAL REAR SHELL

3 G-VACUUM SEAL REAR SHELL-Material G-VACUUM SEAL REAR SHELL-Material

2 G-TIE RODS W/O-RINGS G-TIE RODS W/O-RINGS

3 G-TIE ROD, BRAKE BOOSTER G-TIE ROD, BRAKE BOOSTER

3 G-O-RING, TIE ROD, BOOSTER G-O-RING, TIE ROD, BOOSTER

2 G-CENTER ASSEMBLLY, BOOSTER G-CENTER ASSEMBLLY, BOOSTER

3 G-VALVE BODY ASY BODY G-VALVE BODY ASY BODY

4 G-BODY, VALVE BOOSTER G-BODY, VALVE BOOSTER

5 G-BODY, VALVE BOOSTER-Material G-BODY, VALVE BOOSTER -Material

4 G-INPUT ROD ASY G-INPUT ROD ASY

5 G-INPUT ROD, VALVE BODY G-INPUT ROD, VALVE BODY

6 G-INPUT ROD, VALVE BODY-Machined G-INPUT ROD, VALVE BODY-Machined

7 G-INPUT ROD, VALVE BODY-Machined G-INPUT ROD, VALVE BODY-Material

5 G-RETAINER, INPUT ROD SPRING G-RETAINER, INPUT ROD SPRING
6 G-RETAINER, INPUT ROD SPRING -Material G-RETAINER, INPUT ROD SPRING -Material

5 G- SPRING, INPUT ROD, VALVE BODY G- SPRING, INPUT ROD, VALVE BODY

5 G-RETAINER, POPET SPRING G-RETAINER, POPET SPRING

6 G-RETAINER, POPET SPRING-Material G-RETAINER, POPET SPRING-Material

5 G-SPRING, POPET, VALVE BODY G-SPRING, POPET, VALVE BODY

5 G-POPPET, VALVE BODY G-POPPET, VALVE BODY

6 G-POPPET, VALVE BODY-Material G-POPPET, VALVE BODY-Material

6 G-WASHER, POPPET, VALVE BODY-Material G-WASHER, POPPET, VALVE BODY

5 G-PLUNGER, VALVE BODY G-PLUNGER, VALVE BODY

6 G-PLUNGER, VALVE BODY- Machined G-PLUNGER, VALVE BODY -Machined

7 G-PLUNGER, VALVE BODY BAR STOCK G-PLUNGER, VALVE BODY-Material

5 SEAL, POPPET VALVE H SEAL, POPPET VALVE

4 G KEY, BOOSTER G KEY, BOOSTER

5 G KEY, BOOSTER G KEY, BOOSTER-Material

5 G Metal KEY, BOOSTER G Metal KEY, BOOSTER

6 G Metal KEY, BOOSTER G Metal KEY, BOOSTER-1

4 G-DISK, REACTION, BOOSTER-Molding G-DISK, REACTION, BOOSTER-Molding

5 G-DISK, REACTION, BOOSTER-Material G-DISK, REACTION, BOOSTER-Material

4 GREEN FOAM FILTER VALVE BODY GREEN FOAM FILTER VALVE BODY

4 G-FOAM FILTER, YELLOW, VALVE BODY, G-FOAM FILTER, YELLOW, VALVE BODY,

3 G-CENTER PLATE, BOOSTER G-CENTER PLATE, BOOSTER

4 G-CENTER PLATE, BOOSTER-Stamping G-CENTER PLATE, BOOSTER-Stamping

5 G-CENTER PLATE, BOOSTER -Material G-CENTER PLATE, BOOSTER -Material

3 G-DIAPHRAGM, BOOSTER G-DIAPHRAGM, BOOSTER

4 G-DIAPHRAGM, BOOSTER -Material G-DIAPHRAGM, BOOSTER -Material

2 G-NUT W/ORING BOOSTER G-NUT W/ORING BOOSTER

3 G-NUT, TIE ROD ADJUSTER G-NUT, TIE ROD ADJUSTER

3 G-O-RING, TIE ROD, BOOSTER G-O-RING, TIE ROD, BOOSTER

1 G FOAM SEAL, REAR SHELL G FOAM SEAL, REAR SHELL

1 G-FOAM FILTER, LARGE, BOOSTER G-FOAM FILTER, LARGE, BOOSTER

1 G-EXCLUDER, BOOSTER G-EXCLUDER, BOOSTER

2 G-EXCLUDER, BOOSTER, Material G-EXCLUDER, BOOSTER, Material

1 G-CLEVIS LOCK NUT, BOOSTER G-CLEVIS LOCK NUT, BOOSTER

1 G-CLEVIS TO PEDAL G-CLEVIS TO PEDAL

2 G-CLEVIS TO PEDAL-Machined G-CLEVIS TO PEDAL-Machined

3 G-CLEVIS TO PEDAL-Stamped G-CLEVIS TO PEDAL-Stamped

4 G-CLEVIS TO PEDAL, Material G-CLEVIS TO PEDAL, Material

0 G Master Cylinder Asm G Master Cylinder Asm

0 G Nut, Cylinder to Booster G Nut, Cylinder to Booster

0 G Vacuum Hose, Booster G Vacuum Hose, Booster

Assembly Totals Report Totals

Analyzed Subs: 49

Unanalyzed Subs: 0

Parts: 45

Fasteners:9

Parts+Unanaly 45 zed:

Design Profit®

Page 

Copyright 2005© Munro & Associates, Inc.
Qty Material Piece Cost Weight

1 $5.59

1 Steel - 1008 #

1 Steel - 1008 $1.03

1 Steel - 1008 $1.03

1 Steel - 1008

1 EPDM #

nt Shell, Material 1 EPDM $0.01

1 Nylon 6/6 #

RNT SHELL, MATERIAL 1 Nylon 6/6 $0.02

1 Commodity Pricing #

1 Steel - 1008 #

1 Steel - 1008 $0.03

T ROD,MATERIAL 1 Steel - 1008 $0.03

1 #

1 Steel - 1018 $0.09

1 Steel - 1018 $0.09

1 Steel - 1018

1 Steel - 1018

1 Commodity Pricing $0.01

1 Steel - 1040 $0.02

1 Steel - 1040 $0.02

1 Steel - 1040

1 #

1 $0.91

1 $0.91

1 Steel - 1008

BOOSTER, STAMPED 1 Steel - 1008

1 Steel - 1008

1 Steel - 1008

STUD PLATE-Wash 1 Steel - 1008

R STUD PLATE-Material 1 Steel - 1008

2 Commodity Pricing

1 EPDM $0.04

AR SHELL-Material 1 EPDM $0.04

2 $0.39

1 Commodity Pricing $0.33

1 Commodity Prcing $0.06

1 $1.81

1 MIXED $0.88

1 PET-GF 36

 BOOSTER -Material 1 PET-GF 36

1 MIXED

1 Steel - 1018

, VALVE BODY-Machined 1 Steel - 1018

OD, VALVE BODY-Material 1 Steel - 1018

PUT ROD SPRING 1 Steel - 1008
 INPUT ROD SPRING -Material 1 Steel - 1008

UT ROD, VALVE BODY 1 Commodity Pricing

1 PET-GF 36

 POPET SPRING-Material 1 PET-GF 36

ET, VALVE BODY 1 Commodity Pricing

1 MIXED

ALVE BODY-Material 1 SBR

POPPET, VALVE BODY 1 Commodity Prcing

1 Steel - 1018

VALVE BODY -Machined 1 Steel - 1018

R, VALVE BODY-Material 1 Steel - 1018

1 Commodity Pricing

1

1 EDPM

1 Steel - 1040

1 Steel - 1040

, BOOSTER-Molding 1 SBR

ON, BOOSTER-Material 1 SBR

ER VALVE BODY 1 Commodity Pricing

ELLOW, VALVE BODY, 1 Commodity Pricing

1 Steel - 1008 $0.63

 BOOSTER-Stamping 1 Steel - 1008

TE, BOOSTER -Material 1 Steel - 1008

1 SBR $0.30

OSTER -Material 1 SBR

2 $0.12

1 Commodity Pricing $0.07

1 Commodity Prcing $0.06

1 Commodity Pricing #

1 Commodity Pricing #

1 SBR #

1 SBR $0.05

1 Commodity Pricing #

1 Steel - 1008 #

1 Steel - 1008 $0.07

1 Steel - 1008 $0.07

1 Steel - 1008

1 $0.00

2 Commodity Pricing $0.04

1 $0.00

Report Totals Preassembled Totals

Piece Cost (Total): # Analyzed Subs: 0

Unanalyzed Subs: 0

Weight (Total): 6.3187 lb

Parts: 0

Fasteners: 0

Parts+Unanalyzed: 0

Page 1 of 1
Piece Cost Weight (Total)

(Total)

4.8533 lb ## 4.8533 lb

1.1100 lb # 1.1100 lb

1.1100 lb $1.03 1.1100 lb

1.1100 lb $1.03 1.1100 lb

$1.03 1.1100 lb $1.03 1.1100 lb

0.0078 lb # 0.0078 lb

0.0078 lb $0.01 0.0078 lb

0.0088 lb # 0.0088 lb

0.0088 lb $0.02 0.0088 lb

0.2283 lb # 0.2283 lb

0.0511 lb # 0.0511 lb

0.0511 lb $0.03 0.0511 lb

0.0511 lb $0.03 0.0511 lb

0.1042 lb # 0.1042 lb

0.0996 lb $0.09 0.0996 lb

0.0996 lb $0.09 0.0996 lb

$0.09 0.0996 lb $0.09 0.0996 lb

$0.09 0.0996 lb $0.09 0.0996 lb

0.0004 lb $0.01 0.0004 lb

0.0042 lb $0.02 0.0042 lb

0.0042 lb $0.02 0.0042 lb

$0.02 0.0042 lb $0.02 0.0042 lb

3.2004 lb # 3.2004 lb

1.2781 lb $0.91 1.2781 lb

1.2781 lb $0.91 1.2781 lb

$0.70 0.9683 lb $0.70 0.9683 lb

$0.70 0.9683 lb $0.70 0.9683 lb

$0.70 0.9683 lb $0.70 0.9683 lb

$0.13 0.2348 lb $0.13 0.2348 lb

$0.13 0.2348 lb $0.13 0.2348 lb

$0.13 0.0000 lb $0.13 0.0000 lb

$0.04 0.0375 lb $0.08 0.0750 lb

0.0146 lb $0.04 0.0146 lb

0.0146 lb $0.04 0.0146 lb

0.1575 lb $0.78 0.3150 lb

0.1573 lb $0.67 0.3146 lb

0.0002 lb $0.11 0.0004 lb

1.5427 lb $1.81 1.5427 lb

0.4437 lb $0.88 0.4437 lb

$0.25 0.1792 lb $0.25 0.1792 lb

$0.25 0.1792 lb $0.25 0.1792 lb

$0.42 0.1973 lb $0.42 0.1973 lb

$0.08 0.0890 lb $0.08 0.0890 lb

$0.08 0.0890 lb $0.08 0.0890 lb

$0.08 0.0890 lb $0.08 0.0890 lb

$0.01 0.0054 lb $0.01 0.0054 lb
$0.01 0.0054 lb $0.01 0.0054 lb

$0.07 0.0196 lb $0.07 0.0196 lb

$0.03 0.0149 lb $0.03 0.0149 lb

$0.03 0.0149 lb $0.03 0.0149 lb

$0.04 0.0123 lb $0.04 0.0123 lb

$0.02 0.0145 lb $0.02 0.0145 lb

$0.01 0.0015 lb $0.01 0.0015 lb

$0.01 0.0130 lb $0.01 0.0130 lb

$0.12 0.0410 lb $0.12 0.0410 lb

$0.12 0.0000 lb $0.12 0.0000 lb

$0.12 0.0000 lb $0.12 0.0000 lb

$0.06 0.0006 lb $0.06 0.0006 lb

$0.08 0.0558 lb $0.08 0.0558 lb

$0.01 0.0279 lb $0.01 0.0279 lb

$0.08 0.0279 lb $0.08 0.0279 lb

$0.08 0.0279 lb $0.08 0.0279 lb

$0.01 0.0071 lb $0.01 0.0071 lb

$0.01 0.0071 lb $0.01 0.0071 lb

$0.06 0.0018 lb $0.06 0.0018 lb

$0.05 0.0025 lb $0.05 0.0025 lb

0.8540 lb $0.63 0.8540 lb

$0.63 0.8450 lb $0.63 0.8450 lb

$0.63 0.8450 lb $0.63 0.8450 lb

0.2450 lb $0.30 0.2450 lb

$0.30 0.2450 lb $0.30 0.2450 lb

0.0250 lb $0.25 0.0500 lb

0.0248 lb $0.13 0.0496 lb

0.0002 lb $0.11 0.0004 lb

0.0000 lb # 0.0000 lb

0.0038 lb # 0.0038 lb

0.0400 lb # 0.0400 lb

0.0400 lb $0.05 0.0400 lb

0.0095 lb # 0.0095 lb

0.0894 lb # 0.0894 lb

0.0894 lb $0.07 0.0894 lb

0.0894 lb $0.07 0.0894 lb

$0.07 0.0894 lb $0.07 0.0894 lb

1.1800 lb $0.00 1.1800 lb

0.0102 lb $0.07 0.0204 lb

0.2650 lb $0.00 0.2650 lb


Assembly Report

G Brake Booster Assembly

Labor Type Parent Name Symbol Name

Rate

$35.51 Tool G Brake Booster Assembly First Fixture

$35.51 Subassembly G Brake Booster Assembly G BRAKE BOOSTER

$35.51 Tool G BRAKE BOOSTER First Fixture

$42.18 P.-P. Part G BRAKE BOOSTER G FRONT SHELL, BRAKE BOOSTER

$42.18 Tool G FRONT SHELL, BRAKE BOOSTER First Fixture

- - - Spray Painted

$20.81 P.-P. Part G FRONT SHELL, BRAKE BOOSTER G-FRONT SHELL - Wash

$20.81 Tool G-FRONT SHELL - Wash Washer Turbo Tunnel 

- - - In-Line Washer

$106.69 P.-P. Part G-FRONT SHELL - Wash G-FRONT SHELL - Stamping

$106.69 Tool G-FRONT SHELL - Stamping Stamping Press 800-1k Ton 

$106.69 Part G-FRONT SHELL - Stamping G-REAR SHELL -Material

- - - Blank weight 2.283 lbs

- - - Press Size 1000 Ton & Progressive

- - - Part Size after stamping (270L by 270W by 68H)mm

$20.81 Operation G-FRONT SHELL - Wash Load Part

$20.81 Operation G-FRONT SHELL - Wash Wash Part Medium

$20.81 Operation G-FRONT SHELL - Wash Unload Part

$42.18 Operation G FRONT SHELL, BRAKE BOOSTER Load Part

$42.18 Operation G FRONT SHELL, BRAKE BOOSTER Paint Part Medium

$42.18 Operation G FRONT SHELL, BRAKE BOOSTER Unload Part

- - - G & H SEALS ARE INDENTICAL

$16.39 P.-P. Part G BRAKE BOOSTER G-VAC HOSE SEAL FRNT SHELL

$16.39 Tool G-VAC HOSE SEAL FRNT SHELL Injection Molding Machine 55-150 ton

$16.39 Part G-VAC HOSE SEAL FRNT SHELL G-VAC HOSE SEAL FRNT SHELL -Material

- - - Raw Material Req 0.011lbs from Cost Sheet

- - - 10 Cavity Mold

- - - Box Size 27mm L x 27mm W x 10mm H

$35.51 Fastening G BRAKE BOOSTER Push In Place

$16.39 P.-P. Part G BRAKE BOOSTER G-VAC HOSE FITTING FRNT SHELL

$16.39 Tool G-VAC HOSE FITTING FRNT SHELL Injection Molding Machine 55-150 ton

$16.39 Part G-VAC HOSE FITTING FRNT SHELL G-VAC HOSE FITTING FRNT SHELL, MATERIAL

- - - Raw Material Req 0.013 lbs from Cost Sheet

- - - 10 Cavity Mold

- - - Box Size 41mm L x 22mm W x 22mm H

$35.51 Fastening G BRAKE BOOSTER Push In Place

$35.51 Operation G BRAKE BOOSTER Part Manipulation

$35.51 Part G BRAKE BOOSTER G-SPRING LARGE, BRAKE BOOSTER

$35.51 Fastening G BRAKE BOOSTER Position Part

$10.75 P.-P. Part G BRAKE BOOSTER G-RETAINER, OUTPUT ROD

$10.75 Tool G-RETAINER, OUTPUT ROD Washer Duo 400 Wash Rinse & DRY

$15.50 P.-P. Part G-RETAINER, OUTPUT ROD G-RETAINER, OUTPUT ROD, STAMPED

$15.50 Tool G-RETAINER, OUTPUT ROD, STAMPEDStamping Press 0-60 Ton 

$15.50 Part G-RETAINER, OUTPUT ROD, STAMPEDG-RETAINER, OUTPUT ROD,MATERIAL

- - - Blank weight 0.061lbs

- - - Press Size 25 Ton Progressive

- - - Part Size after stamping (52 L by 52 W by 16 H)mm
$10.75 Operation G-RETAINER, OUTPUT ROD Load Part

$10.75 Operation G-RETAINER, OUTPUT ROD Wash Part Medium

$10.75 Operation G-RETAINER, OUTPUT ROD Unload Part

$35.51 Subassembly G BRAKE BOOSTER G OUTPUT ROD ASM

$35.51 Tool G OUTPUT ROD ASM First Fixture

$10.75 P.-P. Part G OUTPUT ROD ASM G Rod Output

$10.75 Tool G Rod Output Washer Duo 400 Wash Rinse & DRY

$21.43 P.-P. Part G Rod Output G Rod Output, Machined

$21.43 Tool G Rod Output, Machined CNC Turning 2 Axis SL-10, Odd Form

$115.72 P.-P. Part G Rod Output, Machined G Output Rod, Forged

$115.72 Tool G Output Rod, Forged Forging Press 500 Ton

$115.72 Part G Output Rod, Forged G Output Rod, Material

- - - Raw Material Req 0.105 lbs

- - - Box Size 72mm L x 26mm W x 26mm H

- - - One hit based on rough - near net shape

$115.72 Material Mod. G Output Rod, Forged Forge 500T

$21.43 Operation G Rod Output, Machined Clamp Part

- - - Face End End & Turn Max OD

$21.43 Material Mod. G Rod Output, Machined Turn I/D 30-60 mm

$21.43 Operation G Rod Output, Machined Reposition Cutting Tool

$21.43 Material Mod. G Rod Output, Machined Turn End Face 30-60mm

- - - Grab Turned Piece with 2nd Chuck Head

$21.43 Operation G Rod Output, Machined Unclamp Part

$21.43 Operation G Rod Output, Machined Part Manipulation

$21.43 Operation G Rod Output, Machined Clamp Part

- - - Face End End & Turn Min OD

$21.43 Material Mod. G Rod Output, Machined Turn End face 1-30mm

$21.43 Operation G Rod Output, Machined Reposition Cutting Tool

$21.43 Material Mod. G Rod Output, Machined Turn OD 1-30mm

- - - Bevel Face & Drill Hole

$21.43 Operation G Rod Output, Machined Reposition Cutting Tool

$21.43 Material Mod. G Rod Output, Machined Chamfer OD sml

$21.43 Operation G Rod Output, Machined Auto Tool Change

$21.43 Material Mod. G Rod Output, Machined Drill & Chamfer Hole 1-30mm

$21.43 Operation G Rod Output, Machined Unclamp Part

$10.75 Operation G Rod Output Load Part

$10.75 Operation G Rod Output Wash Part Medium

$10.75 Operation G Rod Output Unload Part

$35.51 Part G OUTPUT ROD ASM G Washer, Output Rod, 1.00 mm

$10.75 P.-P. Part G OUTPUT ROD ASM G Socket, Output Rod

$10.75 Tool G Socket, Output Rod Washer Duo 400 Wash Rinse & DRY

$42.68 P.-P. Part G Socket, Output Rod G Socket, Output Rod, Machined

$42.68 Tool G Socket, Output Rod, Machined CNC TL-15 4 Axis Twin Spindle Lathe - Auto Load

- - - Includes Bar Feeder

$42.68 Part G Socket, Output Rod, Machined G Socket, Output Rod, Material

- - - Bar stock weight 0.02 lbs.

- - - Box size of finished part 7mm D x 15mm L

- - - Turn Ball End & Max OD (7mm)

$42.68 Material Mod. G Socket, Output Rod, Machined Milled face

$42.68 Operation G Socket, Output Rod, Machined Reposition Cutting Tool

$42.68 Material Mod. G Socket, Output Rod, Machined Turn OD 1-30mm

- - - Grab Turned Piece with 2nd Chuck Head

$42.68 Operation G Socket, Output Rod, Machined Auto Tool Change

$42.68 Material Mod. G Socket, Output Rod, Machined Cut to Length

- - - Turn Undercut OD (3mm)

$42.68 Operation G Socket, Output Rod, Machined Auto Tool Change
$42.68 Material Mod. G Socket, Output Rod, Machined Turn OD 1-30mm

$42.68 Operation G Socket, Output Rod, Machined Reposition Cutting Tool

- - - Face End & Cut Groove

$42.68 Material Mod. G Socket, Output Rod, Machined Turn End face 1-30mm

$42.68 Operation G Socket, Output Rod, Machined Auto Tool Change

$42.68 Material Mod. G Socket, Output Rod, Machined Cut slot

$10.75 Operation G Socket, Output Rod Load Part

$10.75 Operation G Socket, Output Rod Wash Part Medium

$10.75 Operation G Socket, Output Rod Unload Part

$35.51 Tool G OUTPUT ROD ASM Grease

$35.51 Operation G OUTPUT ROD ASM Apply Lubricant

$35.51 Fastening G OUTPUT ROD ASM Push In Place

$35.51 Subassembly G BRAKE BOOSTER G-REAR ASSEMBLY

$35.51 Tool G-REAR ASSEMBLY First Fixture

$35.51 Subassembly G-REAR ASSEMBLY G SHELL REAR W/STUDS

$35.51 Tool G SHELL REAR W/STUDS First Fixture

- - - Spray Painted

$42.18 Subassembly G SHELL REAR W/STUDS G SHELL REAR W/STUDS-Press

$42.18 Tool G SHELL REAR W/STUDS-Press Press

$20.81 P.-P. Part G SHELL REAR W/STUDS-Press G-SHELL REAR BOOSTER

$20.81 Tool G-SHELL REAR BOOSTER Washer Turbo Tunnel 

$106.69 P.-P. Part G-SHELL REAR BOOSTER G-SHELL REAR BOOSTER, STAMPED

$106.69 Tool G-SHELL REAR BOOSTER, STAMPED Stamping Press 800-1k Ton 

$106.69 Part G-SHELL REAR BOOSTER, STAMPED G SHELL REAR-Material

- - - Blank weight 1.524 lbs

- - - Press Size 1000 Ton & Progressive

- - - Part Size after stamping (268 L by 268W by 78 H)mm

- - - In-Line Washer

$20.81 Operation G-SHELL REAR BOOSTER Load Part

$20.81 Operation G-SHELL REAR BOOSTER Wash Part Medium

$20.81 Operation G-SHELL REAR BOOSTER Unload Part

$20.81 P.-P. Part G SHELL REAR W/STUDS-Press G SHELL REAR STUD PLATE

$20.81 Tool G SHELL REAR STUD PLATE Washer Turbo Tunnel 

$24.60 P.-P. Part G SHELL REAR STUD PLATE G SHELL REAR STUD PLATE-Stamped

$24.60 Tool G SHELL REAR STUD PLATE-Stamped Stamping Press 60-200 Ton 

$24.60 Part G SHELL REAR STUD PLATE-Stamped G SHELL REAR STUD PLATE-Material

- - - Blank weight 0.442 lbs

- - - Press Size 60 Ton & Progressive

- - - Part Size after stamping (136L by 136W by 7H)mm

- - - In-Line Washer

$20.81 Operation G SHELL REAR STUD PLATE Load Part

$20.81 Operation G SHELL REAR STUD PLATE Wash Part Medium

$20.81 Operation G SHELL REAR STUD PLATE Unload Part

$42.18 Part G SHELL REAR W/STUDS-Press G STUD, REAR SHELL

$42.18 Fastening G SHELL REAR W/STUDS-Press Press Together

$35.51 Operation G SHELL REAR W/STUDS Load Part

$35.51 Operation G SHELL REAR W/STUDS Paint Part Medium

$35.51 Operation G SHELL REAR W/STUDS Unload Part

- - - VACUUM SEAL SAME AS HYBRID

$16.39 P.-P. Part G-REAR ASSEMBLY G-VACUUM SEAL REAR SHELL

$16.39 Tool G-VACUUM SEAL REAR SHELL Injection Molding Machine 55-150 ton

$16.39 Part G-VACUUM SEAL REAR SHELL G-VACUUM SEAL REAR SHELL-Material

- - - Raw Material Req 0.019 lbs from Cost Sheet

- - - 10 Cavity Mold

- - - Box Size 54mm L x 54mm W x 12mm H

$35.51 Fastening G-REAR ASSEMBLY Push In Place
$35.51 Operation G-REAR ASSEMBLY Part Manipulation

$35.51 Subassembly G-REAR ASSEMBLY G-TIE RODS W/O-RINGS

$35.51 Tool G-TIE RODS W/O-RINGS First Fixture

- - - TRW AT 0.207 POUNDS COST $0.52

$35.51 Part G-TIE RODS W/O-RINGS G-TIE ROD, BRAKE BOOSTER

$35.51 Tool G-TIE RODS W/O-RINGS Glue Bottle

$35.51 Operation G-TIE RODS W/O-RINGS Apply Lubricant

$35.51 Part G-TIE RODS W/O-RINGS G-O-RING, TIE ROD, BOOSTER

$35.51 Operation G-TIE RODS W/O-RINGS Set O-ring in Place

$35.51 Subassembly G-REAR ASSEMBLY G-CENTER ASSEMBLLY, BOOSTER

$35.51 Tool G-CENTER ASSEMBLLY, BOOSTER First Fixture

$35.51 Subassembly G-CENTER ASSEMBLLY, BOOSTER G-VALVE BODY ASY BODY

$35.51 Tool G-VALVE BODY ASY BODY First Fixture

$28.80 P.-P. Part G-VALVE BODY ASY BODY G-BODY, VALVE BOOSTER

$28.80 Tool G-BODY, VALVE BOOSTER Injection Molding Machine 200-400 Ton

$28.80 Part G-BODY, VALVE BOOSTER G-BODY, VALVE BOOSTER-Material

- - - Raw Material Req 0.209 lbs from Cost Sheet

- - - 4 Cavity Mold

- - - Box Size 106mm L x 67mm W x 67mm H

$35.51 Subassembly G-VALVE BODY ASY BODY G-INPUT ROD ASY

$35.51 Tool G-INPUT ROD ASY First Fixture

- - - OUTPUT ROD & PLUNGER

- - - G AND H ROD ARE SAME

$10.75 P.-P. Part G-INPUT ROD ASY G-INPUT ROD, VALVE BODY

- - - "Washing, Small Size and/or Low Complexity"

$10.75 Tool G-INPUT ROD, VALVE BODY Washer Duo 400 Wash Rinse & DRY

$20.90 P.-P. Part G-INPUT ROD, VALVE BODY G-INPUT ROD, VALVE BODY-Machined

- - - CNC Turning 1.75" Bar 2 Axis

$20.90 Tool G-INPUT ROD, VALVE BODY-Machined CNC Turning 2 Axis SL-10, 1.75" bar

- - - Includes Bar Feeder

$20.90 Part G-INPUT ROD, VALVE BODY-Machined G-INPUT ROD, VALVE BODY-Machined

- - - Bar stock weight 0.15 lbs.

- - - Box size of finished part 10Dmm x 93Lmm

$20.90 Operation G-INPUT ROD, VALVE BODY-Machined Load Part

$20.90 Operation G-INPUT ROD, VALVE BODY-Machined Clamp Part

$20.90 Material Mod. G-INPUT ROD, VALVE BODY-Machined Turn End face 1-30mm

$20.90 Operation G-INPUT ROD, VALVE BODY-Machined Auto Tool Change

Design Profit ®

Page 

Copyright 2005© Munro & Associates, Inc.

G Brake Booster Assembly

Labor Type Parent Name Symbol Name

Rate

$20.90 Material Mod. G-INPUT ROD, VALVE BODY-Machined Turn OD Contoured surface fins

$20.90 Operation G-INPUT ROD, VALVE BODY-Machined Unclamp Part

$20.90 Operation G-INPUT ROD, VALVE BODY-Machined Part Manipulation

$20.90 Operation G-INPUT ROD, VALVE BODY-Machined Clamp Part

$20.90 Material Mod. G-INPUT ROD, VALVE BODY-Machined Turn End face 1-30mm

$20.90 Operation G-INPUT ROD, VALVE BODY-Machined Auto Tool Change

$20.90 Material Mod. G-INPUT ROD, VALVE BODY-Machined Turn Threads

$20.90 Operation G-INPUT ROD, VALVE BODY-Machined Unclamp Part

$20.90 Operation G-INPUT ROD, VALVE BODY-Machined Unload Part
- - - Batch Type Washer

- - - 5-10 min cycle time

- - - Basket Size 15.75x18.50x25.50 inches x 2

$10.75 Operation G-INPUT ROD, VALVE BODY Load Part

$10.75 Operation G-INPUT ROD, VALVE BODY Wash Part Medium

$10.75 Operation G-INPUT ROD, VALVE BODY Unload Part

$15.50 P.-P. Part G-INPUT ROD ASY G-RETAINER, INPUT ROD SPRING

$15.50 Tool G-RETAINER, INPUT ROD SPRING Stamping Press 0-60 Ton 

$15.50 Part G-RETAINER, INPUT ROD SPRING G-RETAINER, INPUT ROD SPRING -Material

- - - Blank weight 0.016 lbs

- - - Press Size 25 Ton & Progressive

- - - Part Size after stamping (28 L by 28 W by 1 H)mm

$35.51 Part G-INPUT ROD ASY G- SPRING, INPUT ROD, VALVE BODY

$16.39 P.-P. Part G-INPUT ROD ASY G-RETAINER, POPET SPRING

$16.39 Tool G-RETAINER, POPET SPRING Injection Molding Machine 55-150 ton

$16.39 Part G-RETAINER, POPET SPRING G-RETAINER, POPET SPRING-Material

- - - Raw Material Req 0.021 lbs from Cost Sheet

- - - 10 Cavity Mold

- - - Box Size 36mm L x 36mm W x 19mm H

$35.51 Part G-INPUT ROD ASY G-SPRING, POPET, VALVE BODY

$16.39 P.-P. Part G-INPUT ROD ASY G-POPPET, VALVE BODY

$16.39 Tool G-POPPET, VALVE BODY Injection Molding Machine 55-150 ton

- - - INSERT MOLDING

$16.39 Part G-POPPET, VALVE BODY G-POPPET, VALVE BODY-Material

- - - G & H WASHER ARE SAME

$16.39 Part G-POPPET, VALVE BODY G-WASHER, POPPET, VALVE BODY-Material

- - - Raw Material Req 0.02lbs from Cost Sheet

- - - 8 Cavity Mold

- - - Box Size 30mm L x 30mm W x 7mm H

$35.51 Fastening G-INPUT ROD ASY COMPRESS SPRINGS

$10.75 P.-P. Part G-INPUT ROD ASY G-PLUNGER, VALVE BODY

$10.75 Tool G-PLUNGER, VALVE BODY Washer Duo 400 Wash Rinse & DRY

$20.90 P.-P. Part G-PLUNGER, VALVE BODY G-PLUNGER, VALVE BODY- Machined

$20.90 Tool G-PLUNGER, VALVE BODY- Machined CNC Turning 2 Axis SL-10, 1.75" bar

$20.90 Part G-PLUNGER, VALVE BODY- Machined G-PLUNGER, VALVE BODY BAR STOCK

- - - Includes Bar Feeder

- - - Bar stock weight 0.22 lbs.

- - - Box size of finished part 22Dmm x 24Lmm

$20.90 Operation G-PLUNGER, VALVE BODY- Machined Load Part

$20.90 Operation G-PLUNGER, VALVE BODY- Machined Clamp Part

$20.90 Material Mod. G-PLUNGER, VALVE BODY- Machined Turn end face 1-30mm

$20.90 Operation G-PLUNGER, VALVE BODY- Machined Auto Tool Change

$20.90 Material Mod. G-PLUNGER, VALVE BODY- Machined Turn OD 30-60mm

$20.90 Operation G-PLUNGER, VALVE BODY- Machined Auto Tool Change

$20.90 Material Mod. G-PLUNGER, VALVE BODY- Machined Turn OD Contoured surface fins

$20.90 Operation G-PLUNGER, VALVE BODY- Machined Auto Tool Change

$20.90 Material Mod. G-PLUNGER, VALVE BODY- Machined Drill & Chamfer Hole 1-30mm

$20.90 Operation G-PLUNGER, VALVE BODY- Machined Auto Tool Change

$20.90 Material Mod. G-PLUNGER, VALVE BODY- Machined Bore Hole 1-30mm

$20.90 Operation G-PLUNGER, VALVE BODY- Machined Unclamp Part

$20.90 Operation G-PLUNGER, VALVE BODY- Machined Part Manipulation

$20.90 Operation G-PLUNGER, VALVE BODY- Machined Clamp Part

$20.90 Material Mod. G-PLUNGER, VALVE BODY- Machined Turn end face 1-30mm

$20.90 Operation G-PLUNGER, VALVE BODY- Machined Unclamp Part

- - - Batch Type Washer

- - - 5-10 min cycle time
- - - Basket Size 15.75x18.50x25.50 inches x 2

$10.75 Operation G-PLUNGER, VALVE BODY Load Part

$10.75 Operation G-PLUNGER, VALVE BODY Wash Part Medium

$10.75 Operation G-PLUNGER, VALVE BODY Unload Part

$35.51 Operation G-INPUT ROD ASY CDI

$35.51 Tool G-INPUT ROD ASY Special Tool

$35.51 Fastening G-INPUT ROD ASY Gross Deform

- - - SEAL IS COMMON TO G & H

$35.51 Part G-INPUT ROD ASY SEAL, POPPET VALVE

$35.51 Tool G-INPUT ROD ASY Grease

$35.51 Fastening G-INPUT ROD ASY APPLY GREASE

$35.51 Tool G-VALVE BODY ASY BODY Grease

$35.51 Fastening G-VALVE BODY ASY BODY APPLY GREASE

$35.51 Fastening G-VALVE BODY ASY BODY Push In Place

$35.51 Operation G-VALVE BODY ASY BODY CDI

$16.39 P.-P. Part G-VALVE BODY ASY BODY G KEY, BOOSTER

$16.39 Tool G KEY, BOOSTER Injection Molding Machine 55-150 ton

- - - INSERT MOLDING

$16.39 Part G KEY, BOOSTER G KEY, BOOSTER

$16.39 Fastening G KEY, BOOSTER Set In Place

$15.50 P.-P. Part G KEY, BOOSTER G Metal KEY, BOOSTER

$15.50 Tool G Metal KEY, BOOSTER Stamping Press 0-60 Ton 

$15.50 Part G Metal KEY, BOOSTER G Metal KEY, BOOSTER

- - - Blank weight 0.103 lbs

- - - Press Size 60 Ton & Progressive

- - - Part Size after stamping (54 L by 20 W by 4 H)mm

- - - Raw Material Req 0.006 lbs from Cost Sheet

- - - 10 Cavity Mold

- - - Box Size 54mm L x 20mm W x 4mm H

$35.51 Fastening G-VALVE BODY ASY BODY Push On

$35.51 Operation G-VALVE BODY ASY BODY Part Manipulation

$16.39 P.-P. Part G-VALVE BODY ASY BODY G-DISK, REACTION, BOOSTER-Molding

$16.39 Tool G-DISK, REACTION, BOOSTER-Molding Injection Molding Machine 55-150 ton

$16.39 Part G-DISK, REACTION, BOOSTER-Molding G-DISK, REACTION, BOOSTER-Material

- - - Raw Material Req 0.010 lbs from Cost Sheet

- - - 10 Cavity Mold

- - - Box Size 26mm L x 26mm W x 6mm H

$35.51 Operation G-VALVE BODY ASY BODY Part Manipulation

- - - GREEN FOAM IS COMMON G & H

$35.51 Part G-VALVE BODY ASY BODY GREEN FOAM FILTER VALVE BODY

$35.51 Fastening G-VALVE BODY ASY BODY Push On

$35.51 Part G-VALVE BODY ASY BODY G-FOAM FILTER, YELLOW, VALVE BODY,

$35.51 Fastening G-VALVE BODY ASY BODY Push On

$20.81 P.-P. Part G-CENTER ASSEMBLLY, BOOSTER G-CENTER PLATE, BOOSTER

$20.81 Tool G-CENTER PLATE, BOOSTER Washer Turbo Tunnel 

- - - In-Line Washer

$42.91 P.-P. Part G-CENTER PLATE, BOOSTER G-CENTER PLATE, BOOSTER-Stamping

$42.91 Tool G-CENTER PLATE, BOOSTER-StampingStamping Press 200-400 Ton 

$42.91 Part G-CENTER PLATE, BOOSTER-StampingG-CENTER PLATE, BOOSTER -Material

- - - Blank weight 1.378 lbs

- - - Press Size 200 Ton & Progressive

- - - Part Size after stamping (240 L by 240W by 24 H)mm

$20.81 Operation G-CENTER PLATE, BOOSTER Load Part

$20.81 Operation G-CENTER PLATE, BOOSTER Wash Part Medium

$20.81 Operation G-CENTER PLATE, BOOSTER Unload Part

$35.51 Operation G-CENTER ASSEMBLLY, BOOSTER CDI
$35.51 Tool G-CENTER ASSEMBLLY, BOOSTER CRIMP TOOL

$35.51 Fastening G-CENTER ASSEMBLLY, BOOSTER Crimp Connector, Large

$35.51 Operation G-CENTER ASSEMBLLY, BOOSTER CDI

$90.59 P.-P. Part G-CENTER ASSEMBLLY, BOOSTER G-DIAPHRAGM, BOOSTER

$90.59 Tool G-DIAPHRAGM, BOOSTER Inj Molding Machine 800-1500 Ton

$90.59 Part G-DIAPHRAGM, BOOSTER G-DIAPHRAGM, BOOSTER -Material

- - - Raw Material Req 0.275 lbs from Cost Sheet

- - - 4 Cavity Mold

- - - Box Size 254mm L x 254mm W x 29mm H

$35.51 Fastening G-CENTER ASSEMBLLY, BOOSTER Push On

$35.51 Tool G-CENTER ASSEMBLLY, BOOSTER Grease

$35.51 Fastening G-CENTER ASSEMBLLY, BOOSTER APPLY GREASE

$35.51 Fastening G-REAR ASSEMBLY Press Together

$35.51 Subassembly G-REAR ASSEMBLY G-NUT W/ORING BOOSTER

$35.51 Tool G-NUT W/ORING BOOSTER First Fixture

$35.51 Part G-NUT W/ORING BOOSTER G-NUT, TIE ROD ADJUSTER

$35.51 Tool G-NUT W/ORING BOOSTER Glue Bottle

$35.51 Operation G-NUT W/ORING BOOSTER Apply Lubricant

$35.51 Part G-NUT W/ORING BOOSTER G-O-RING, TIE ROD, BOOSTER

$35.51 Operation G-NUT W/ORING BOOSTER Set O-ring in Place

$35.51 Fastening G-REAR ASSEMBLY Manual Screw

$35.51 Fastening G BRAKE BOOSTER Push In Place

$35.51 Tool G BRAKE BOOSTER Special Tool

$35.51 Fastening G BRAKE BOOSTER Crimp tabs

$35.51 Operation G BRAKE BOOSTER Part Manipulation

- - - G & H FOAM SEALS ARE IDENTICAL

$35.51 Part G BRAKE BOOSTER G FOAM SEAL, REAR SHELL

$35.51 Fastening G BRAKE BOOSTER Push In Place

- - - COST OF FILTER BASED ON PREVIOUS CBOM

$35.51 Part G BRAKE BOOSTER G-FOAM FILTER, LARGE, BOOSTER

$35.51 Fastening G BRAKE BOOSTER Push In Place

$16.39 P.-P. Part G BRAKE BOOSTER G-EXCLUDER, BOOSTER

$16.39 Tool G-EXCLUDER, BOOSTER Injection Molding Machine 55-150 ton

$16.39 Part G-EXCLUDER, BOOSTER G-EXCLUDER, BOOSTER, Material

- - - Raw Material Req 0.049 lbs from Cost Sheet

- - - 10 Cavity Mold

- - - Box Size 53mm L x 53mm W x 65mm H

$35.51 Part G BRAKE BOOSTER G-CLEVIS LOCK NUT, BOOSTER

$35.51 Fastening G BRAKE BOOSTER Manual Screw

$10.75 P.-P. Part G BRAKE BOOSTER G-CLEVIS TO PEDAL

$10.75 Tool G-CLEVIS TO PEDAL Washer Duo 400 Wash Rinse & DRY

$31.33 P.-P. Part G-CLEVIS TO PEDAL G-CLEVIS TO PEDAL-Machined

- - - "CNC Horz Mach, Man Sml Size and/or Low Compl

- - - Pallet Size 300 mm square, 550 lb Capacity

$31.33 Tool G-CLEVIS TO PEDAL-Machined EC-300-ML Horizontal CNC Machine

$15.50 P.-P. Part G-CLEVIS TO PEDAL-Machined G-CLEVIS TO PEDAL-Stamped

$15.50 Tool G-CLEVIS TO PEDAL-Stamped First Fixture

$15.50 Tool G-CLEVIS TO PEDAL-Stamped Stamping Press 0-60 Ton 

$15.50 Part G-CLEVIS TO PEDAL-Stamped G-CLEVIS TO PEDAL, Material

- - - Blank weight 0.155 lbs

- - - Press Size 60 Ton Progressive

- - - Part Size after stamping (38 L by 23 W by 23 H)mm

$31.33 Operation G-CLEVIS TO PEDAL-Machined Load Part

$31.33 Operation G-CLEVIS TO PEDAL-Machined Clamp Part

$31.33 Material Mod. G-CLEVIS TO PEDAL-Machined Drill and Tap Hole 1-30mm

$31.33 Operation G-CLEVIS TO PEDAL-Machined Unclamp Part
$31.33 Operation G-CLEVIS TO PEDAL-Machined Unload Part

$10.75 Operation G-CLEVIS TO PEDAL Load Part

$10.75 Operation G-CLEVIS TO PEDAL Wash Part Medium

$10.75 Operation G-CLEVIS TO PEDAL Unload Part

$35.51 Fastening G BRAKE BOOSTER Manual Screw

$35.51 Tool G BRAKE BOOSTER Hand Tool

$35.51 Fastening G BRAKE BOOSTER Power Screw

$83.31 Subassembly G Brake Booster Assembly G Master Cylinder Asm

$83.31 Tool G Master Cylinder Asm First Fixture

$35.51 Part G Brake Booster Assembly G Nut, Cylinder to Booster

$35.51 Tool G Brake Booster Assembly Power Tool

$35.51 Fastening G Brake Booster Assembly Power Screw

$35.51 Tool G Brake Booster Assembly Paint Marker

$35.51 Operation G Brake Booster Assembly Mark Part

$83.31 Subassembly G Brake Booster Assembly G Vacuum Hose, Booster

$83.31 Tool G Vacuum Hose, Booster First Fixture

- - - Hoses & check valve are different, should we cost?

$35.51 Fastening G Brake Booster Assembly Push Tube in place

$35.51 Tool G Brake Booster Assembly Hand Tool

$35.51 Fastening G Brake Booster Assembly Position Clamp

$35.51 Tool G Brake Booster Assembly Paint Marker

$35.51 Operation G Brake Booster Assembly Mark Part

Design Profit ®

Page 

Copyright 2005© Munro & Associates, Inc.

G Brake Booster Assembly

Labor Type Parent Name Symbol Name

Rate

Report Totals



Design Profit

®

Page 

Copyright 2005© Munro & Associates, Inc.
Number Munro Actual Time Piece Cost Total Labor 

Score Cost

0.0000 sec 0.0000 sec $0.00 $0.00

G BRAKE BOOSTER 6.0000 sec 6.0000 sec - $0.06

0.0000 sec 0.0000 sec $0.00 $0.00

G FRONT SHELL, BRAKE BOOSTER 5.0000 sec 5.0000 sec - $0.05

0.0000 sec 0.0000 sec $0.00 $0.00

- - - - -

G-FRONT SHELL -Wash 3.0000 sec 3.0000 sec - $0.04

0.0000 sec 0.0000 sec $0.00 $0.00

- - - - -

G-FRONT SHELL -Stamping 3.0000 sec 3.0000 sec - $0.02

0.0000 sec 0.0000 sec $0.00 $0.00

G-REAR SHELL -Material 0.0000 sec 7.3000 sec $1.03 $0.22

- - - - -

- - - - -

- - - - -

3.0000 sec 3.0000 sec $0.00 $0.02

5.0000 sec 5.0000 sec $0.00 $0.03

2.0000 sec 2.0000 sec $0.00 $0.01

3.0000 sec 3.0000 sec $0.00 $0.04

5.0000 sec 5.0000 sec $0.00 $0.06

2.0000 sec 2.0000 sec $0.00 $0.02

- - - - -

G Vacuum Hose Seal, Front Shell 6.0000 sec 6.0000 sec - $0.06

0.0000 sec 0.0000 sec $0.00 $0.00

H Vacuum Hose Seal, Front Shell, Material 0.0000 sec 3.2070 sec $0.01 $0.01

- - - - -

- - - - -

- - - - -

2.0000 sec 2.0000 sec $0.00 $0.02

G-VAC HOSE FITTING FRNT SHELL 5.0000 sec 5.0000 sec - $0.05

0.0000 sec 0.0000 sec $0.00 $0.00

G-VAC HOSE FITTING FRNT SHELL, MATERIAL 0.0000 sec 3.2520 sec $0.02 $0.01

- - - - -

- - - - -

- - - - -

2.0000 sec 2.0000 sec $0.00 $0.02

3.0000 sec 3.0000 sec $0.00 $0.03

G-SPRING LARGE, BRAKE BOOSTER 6.0000 sec 6.0000 sec $0.26 $0.06

1.0000 sec 1.0000 sec $0.00 $0.01

G-RETAINER, OUTPUT ROD7.0000 sec 7.0000 sec - $0.07

0.0000 sec 0.0000 sec $0.00 $0.00

G-RETAINER, OUTPUT ROD, STAMPED 3.0000 sec 3.0000 sec - $0.01

0.0000 sec 0.0000 sec $0.00 $0.00

G-RETAINER, OUTPUT ROD,MATERIAL 0.0000 sec 0.6000 sec $0.03 $0.00

- - - - -

- - - - -

- - - - -
3.0000 sec 3.0000 sec $0.00 $0.01

5.0000 sec 5.0000 sec $0.00 $0.01

2.0000 sec 2.0000 sec $0.00 $0.01

G OUTPUT ROD ASM 5.0000 sec 5.0000 sec - $0.05

0.0000 sec 0.0000 sec $0.00 $0.00

G Rod Output 3.0000 sec 3.0000 sec - $0.03

0.0000 sec 0.0000 sec $0.00 $0.00

G Rod Output, Machined 3.0000 sec 3.0000 sec - $0.01

0.0000 sec 0.0000 sec $0.00 $0.00

G Output Rod, Forged 3.0000 sec 3.0000 sec - $0.02

0.0000 sec 0.0000 sec $0.00 $0.00

G Output Rod, Material 0.0000 sec 0.0000 sec $0.09 $0.00

- - - - -

- - - - -

- - - - -

0.8500 sec 0.8500 sec $0.00 $0.03

3.0000 sec 3.0000 sec $0.00 $0.02

- - - - -

1.0000 sec 1.0000 sec $0.00 $0.01

2.0000 sec 2.0000 sec $0.00 $0.01

4.0000 sec 4.0000 sec $0.00 $0.02

- - - - -

1.0000 sec 1.0000 sec $0.00 $0.01

3.0000 sec 3.0000 sec $0.00 $0.02

3.0000 sec 3.0000 sec $0.00 $0.02

- - - - -

2.0000 sec 2.0000 sec $0.00 $0.01

2.0000 sec 2.0000 sec $0.00 $0.01

1.0000 sec 1.0000 sec $0.00 $0.01

- - - - -

2.0000 sec 2.0000 sec $0.00 $0.01

1.0000 sec 1.0000 sec $0.00 $0.01

5.0000 sec 5.0000 sec $0.00 $0.03

1.0000 sec 1.0000 sec $0.00 $0.01

1.0000 sec 1.0000 sec $0.00 $0.01

3.0000 sec 3.0000 sec $0.00 $0.01

5.0000 sec 5.0000 sec $0.00 $0.01

2.0000 sec 2.0000 sec $0.00 $0.01

G Washer, Output Rod, 1.00 mm6.0000 sec 6.0000 sec $0.01 $0.06

G Socket, Output Rod 6.0000 sec 6.0000 sec - $0.06

0.0000 sec 0.0000 sec $0.00 $0.00

G Socket, Output Rod, Machined 3.0000 sec 3.0000 sec - $0.01

0.0000 sec 0.0000 sec $0.00 $0.00

- - - - -

G Socket, Output Rod, Material 0.0000 sec 0.0000 sec $0.02 $0.00

- - - - -

- - - - -

- - - - -

1.0000 sec 1.0000 sec $0.00 $0.01

2.0000 sec 2.0000 sec $0.00 $0.02

1.0000 sec 1.0000 sec $0.00 $0.01

- - - - -

5.0000 sec 5.0000 sec $0.00 $0.06

1.0000 sec 1.0000 sec $0.00 $0.01

- - - - -

5.0000 sec 5.0000 sec $0.00 $0.06
1.0000 sec 1.0000 sec $0.00 $0.01

2.0000 sec 2.0000 sec $0.00 $0.02

- - - - -

2.0000 sec 2.0000 sec $0.00 $0.02

5.0000 sec 5.0000 sec $0.00 $0.06

1.0000 sec 1.0000 sec $0.00 $0.01

3.0000 sec 3.0000 sec $0.00 $0.01

5.0000 sec 5.0000 sec $0.00 $0.01

2.0000 sec 2.0000 sec $0.00 $0.01

6.0000 sec 6.0000 sec $0.00 $0.06

1.0000 sec 1.0000 sec $0.00 $0.01

2.0000 sec 2.0000 sec $0.00 $0.02

G-REAR ASSEMBLY 8.0000 sec 8.0000 sec - $0.08

0.0000 sec 0.0000 sec $0.00 $0.00

G SHELL REAR W/STUDS 2.0000 sec 2.0000 sec - $0.02

0.0000 sec 0.0000 sec $0.00 $0.00

- - - - -

G SHELL REAR W/STUDS-Press 3.0000 sec 3.0000 sec - $0.03

0.0000 sec 0.0000 sec $0.00 $0.00

G-SHELL REAR BOOSTER 5.0000 sec 5.0000 sec - $0.06

0.0000 sec 0.0000 sec $0.00 $0.00

G-SHELL REAR BOOSTER, STAMPED 3.0000 sec 3.0000 sec - $0.02

0.0000 sec 0.0000 sec $0.00 $0.00

G SHELL REAR-Material 0.0000 sec 7.3000 sec $0.70 $0.22

- - - - -

- - - - -

- - - - -

- - - - -

3.0000 sec 3.0000 sec $0.00 $0.02

5.0000 sec 5.0000 sec $0.00 $0.03

2.0000 sec 2.0000 sec $0.00 $0.01

G SHELL REAR STUD PLATE2.0000 sec 2.0000 sec - $0.02

0.0000 sec 0.0000 sec $0.00 $0.00

G SHELL REAR STUD PLATE-W3.0000 sec ash 3.0000 sec - $0.02

0.0000 sec 0.0000 sec $0.00 $0.00

G SHELL REAR STUD PLATE-Material 0.0000 sec 2.3000 sec $0.13 $0.02

- - - - -

- - - - -

- - - - -

- - - - -

3.0000 sec 3.0000 sec $0.00 $0.02

5.0000 sec 5.0000 sec $0.00 $0.03

2.0000 sec 2.0000 sec $0.00 $0.01

G STUD, REAR SHELL 3.0000 sec 3.0000 sec $0.04 $0.04

3.0000 sec 3.0000 sec $0.00 $0.04

3.0000 sec 3.0000 sec $0.00 $0.03

5.0000 sec 5.0000 sec $0.00 $0.05

2.0000 sec 2.0000 sec $0.00 $0.02

- - - - -

G-VACUUM SEAL REAR SHELL 6.0000 sec 6.0000 sec - $0.06

0.0000 sec 0.0000 sec $0.00 $0.00

G-VACUUM SEAL REAR SHELL-Material 0.0000 sec 2.3810 sec $0.04 $0.01

- - - - -

- - - - -

- - - - -

2.0000 sec 2.0000 sec $0.00 $0.02
3.0000 sec 3.0000 sec $0.00 $0.03

G-TIE RODS W/O-RINGS 7.0000 sec 7.0000 sec - $0.07

0.0000 sec 0.0000 sec $0.00 $0.00

- - - - -

G-TIE ROD, BRAKE BOOSTER5.0000 sec 5.0000 sec $0.33 $0.05

3.0000 sec 3.0000 sec $0.00 $0.03

1.0000 sec 1.0000 sec $0.00 $0.01

G-O-RING, TIE ROD, BOOSTER 4.0000 sec 4.0000 sec $0.06 $0.04

2.0000 sec 2.0000 sec $0.00 $0.02

G-CENTER ASSEMBLLY, BOOSTER 10.0000 sec 10.0000 sec - $0.10

0.0000 sec 0.0000 sec $0.00 $0.00

G-VALVE BODY ASY BODY 7.0000 sec 7.0000 sec - $0.07

0.0000 sec 0.0000 sec $0.00 $0.00

G-BODY, VALVE BOOSTER 5.0000 sec 5.0000 sec - $0.05

0.0000 sec 0.0000 sec $0.00 $0.00

G-BODY, VALVE BOOSTER -Material 0.0000 sec 163.2910 $0.25 $1.31

sec

- - - - -

- - - - -

- - - - -

G-INPUT ROD ASY 7.0000 sec 7.0000 sec - $0.07

0.0000 sec 0.0000 sec $0.00 $0.00

- - - - -

- - - - -

G-INPUT ROD, VALVE BODY5.0000 sec 5.0000 sec - $0.05

- - - - -

0.0000 sec 0.0000 sec $0.00 $0.00

G-INPUT ROD, VALVE BODY-Machined 3.0000 sec 3.0000 sec - $0.01

- - - - -

0.0000 sec 0.0000 sec $0.00 $0.00

- - - - -

G-INPUT ROD, VALVE BODY-Material 0.0000 sec 0.0000 sec $0.08 $0.00

- - - - -

- - - - -

3.0000 sec 3.0000 sec $0.00 $0.02

3.0000 sec 3.0000 sec $0.00 $0.02

2.0000 sec 2.0000 sec $0.00 $0.01

5.0000 sec 5.0000 sec $0.00 $0.03

Page 1 of 3

Number Munro Actual Time Piece Cost Total Labor 

Score Cost

5.0000 sec 5.0000 sec $0.00 $0.03

1.0000 sec 1.0000 sec $0.00 $0.01

3.0000 sec 3.0000 sec $0.00 $0.02

3.0000 sec 3.0000 sec $0.00 $0.02

2.0000 sec 2.0000 sec $0.00 $0.01

5.0000 sec 5.0000 sec $0.00 $0.03

2.0000 sec 2.0000 sec $0.00 $0.01

1.0000 sec 1.0000 sec $0.00 $0.01

2.0000 sec 2.0000 sec $0.00 $0.01
- - - - -

- - - - -

- - - - -

3.0000 sec 3.0000 sec $0.00 $0.01

5.0000 sec 5.0000 sec $0.00 $0.01

2.0000 sec 2.0000 sec $0.00 $0.01

G-RETAINER, INPUT ROD SPRING 3.0000 sec 3.0000 sec - $0.03

0.0000 sec 0.0000 sec $0.00 $0.00

G-RETAINER, INPUT ROD SPRING -Material 0.0000 sec 0.6000 sec $0.01 $0.00

- - - - -

- - - - -

- - - - -

G- SPRING, INPUT ROD, VALVE BODY 4.0000 sec 4.0000 sec $0.07 $0.04

G-RETAINER, POPET SPRING2.0000 sec 2.0000 sec - $0.02

0.0000 sec 0.0000 sec $0.00 $0.00

G-RETAINER, POPET SPRING-Material 0.0000 sec 0.9730 sec $0.03 $0.00

- - - - -

- - - - -

- - - - -

G-SPRING, POPET, VALVE BODY 4.0000 sec 4.0000 sec $0.04 $0.04

G-POPPET, VALVE BODY 2.0000 sec 2.0000 sec - $0.02

0.0000 sec 0.0000 sec $0.00 $0.00

- - - - -

G-POPPET, VALVE BODY-Material 0.0000 sec 0.0000 sec $0.01 $0.00

- - - - -

G-WASHER, POPPET, VALVE BODY 5.0000 sec 5.0000 sec $0.01 $0.02

- - - - -

- - - - -

- - - - -

3.0000 sec 3.0000 sec $0.00 $0.03

G-PLUNGER, VALVE BODY 5.0000 sec 5.0000 sec - $0.05

0.0000 sec 0.0000 sec $0.00 $0.00

G-PLUNGER, VALVE BODY -Machined 3.0000 sec 3.0000 sec - $0.01

0.0000 sec 0.0000 sec $0.00 $0.00

G-PLUNGER, VALVE BODY-Material 0.0000 sec 0.0000 sec $0.12 $0.00

- - - - -

- - - - -

- - - - -

3.0000 sec 3.0000 sec $0.00 $0.02

3.0000 sec 3.0000 sec $0.00 $0.02

2.0000 sec 2.0000 sec $0.00 $0.01

5.0000 sec 5.0000 sec $0.00 $0.03

2.0000 sec 2.0000 sec $0.00 $0.01

5.0000 sec 5.0000 sec $0.00 $0.03

5.0000 sec 5.0000 sec $0.00 $0.03

5.0000 sec 5.0000 sec $0.00 $0.03

1.0000 sec 1.0000 sec $0.00 $0.01

5.0000 sec 5.0000 sec $0.00 $0.03

1.0000 sec 1.0000 sec $0.00 $0.01

1.0000 sec 1.0000 sec $0.00 $0.01

3.0000 sec 3.0000 sec $0.00 $0.02

3.0000 sec 3.0000 sec $0.00 $0.02

2.0000 sec 2.0000 sec $0.00 $0.01

1.0000 sec 1.0000 sec $0.00 $0.01

- - - - -

- - - - -
- - - - -

3.0000 sec 3.0000 sec $0.00 $0.01

5.0000 sec 5.0000 sec $0.00 $0.01

2.0000 sec 2.0000 sec $0.00 $0.01

1.0000 sec 1.0000 sec $0.00 $0.01

6.0000 sec 6.0000 sec $0.00 $0.06

5.0000 sec 5.0000 sec $0.00 $0.05

- - - - -

H SEAL, POPPET VALVE 2.0000 sec 2.0000 sec $0.06 $0.02

6.0000 sec 6.0000 sec $0.00 $0.06

5.0000 sec 5.0000 sec $0.00 $0.05

6.0000 sec 6.0000 sec $0.00 $0.06

5.0000 sec 5.0000 sec $0.00 $0.05

2.0000 sec 2.0000 sec $0.00 $0.02

1.0000 sec 1.0000 sec $0.00 $0.01

G KEY, BOOSTER 6.0000 sec 6.0000 sec - $0.06

0.0000 sec 0.0000 sec $0.00 $0.00

- - - - -

G KEY, BOOSTER-Material 0.0000 sec 0.7620 sec $0.01 $0.00

1.0000 sec 1.0000 sec $0.00 $0.00

G Metal KEY, BOOSTER 3.0000 sec 3.0000 sec - $0.01

0.0000 sec 0.0000 sec $0.00 $0.00

G Metal KEY, BOOSTER-1 0.0000 sec 0.7000 sec $0.08 $0.00

- - - - -

- - - - -

- - - - -

- - - - -

- - - - -

- - - - -

2.0000 sec 2.0000 sec $0.00 $0.02

3.0000 sec 3.0000 sec $0.00 $0.03

G-DISK, REACTION, BOOSTER-Molding 5.0000 sec 5.0000 sec - $0.05

0.0000 sec 0.0000 sec $0.00 $0.00

G-DISK, REACTION, BOOSTER-Material 0.0000 sec 8.0400 sec $0.01 $0.04

- - - - -

- - - - -

- - - - -

3.0000 sec 3.0000 sec $0.00 $0.03

- - - - -

GREEN FOAM FILTER VALVE BODY 5.0000 sec 5.0000 sec $0.06 $0.05

2.0000 sec 2.0000 sec $0.00 $0.02

G-FOAM FILTER, YELLOW, VALVE BODY, 5.0000 sec 5.0000 sec $0.05 $0.05

2.0000 sec 2.0000 sec $0.00 $0.02

G-CENTER PLATE, BOOSTER7.0000 sec 7.0000 sec - $0.07

0.0000 sec 0.0000 sec $0.00 $0.00

- - - - -

G-CENTER PLATE, BOOSTER-Stamping 3.0000 sec 3.0000 sec - $0.02

0.0000 sec 0.0000 sec $0.00 $0.00

G-CENTER PLATE, BOOSTER -Material 0.0000 sec 1.7000 sec $0.63 $0.02

- - - - -

- - - - -

- - - - -

3.0000 sec 3.0000 sec $0.00 $0.02

5.0000 sec 5.0000 sec $0.00 $0.03

2.0000 sec 2.0000 sec $0.00 $0.01

1.0000 sec 1.0000 sec $0.00 $0.01
6.0000 sec 6.0000 sec $0.00 $0.06

4.0000 sec 4.0000 sec $0.00 $0.04

1.0000 sec 1.0000 sec $0.00 $0.01

G-DIAPHRAGM, BOOSTER10.0000 sec 10.0000 sec - $0.10

0.0000 sec 0.0000 sec $0.00 $0.00

G-DIAPHRAGM, BOOSTER -Material 2.0000 sec 3.2330 sec $0.30 $0.08

- - - - -

- - - - -

- - - - -

2.0000 sec 2.0000 sec $0.00 $0.02

6.0000 sec 6.0000 sec $0.00 $0.06

5.0000 sec 5.0000 sec $0.00 $0.05

3.0000 sec 3.0000 sec $0.00 $0.03

G-NUT W/ORING BOOSTER6.0000 sec 6.0000 sec - $0.06

0.0000 sec 0.0000 sec $0.00 $0.00

G-NUT, TIE ROD ADJUSTER6.0000 sec 6.0000 sec $0.07 $0.06

3.0000 sec 3.0000 sec $0.00 $0.03

1.0000 sec 1.0000 sec $0.00 $0.01

G-O-RING, TIE ROD, BOOSTER 4.0000 sec 4.0000 sec $0.06 $0.04

2.0000 sec 2.0000 sec $0.00 $0.02

7.0000 sec 7.0000 sec $0.00 $0.07

2.0000 sec 2.0000 sec $0.00 $0.02

0.0000 sec 0.0000 sec $0.00 $0.00

1.0000 sec 1.0000 sec $0.00 $0.01

3.0000 sec 3.0000 sec $0.00 $0.03

- - - - -

G FOAM SEAL, REAR SHELL7.0000 sec 7.0000 sec $0.06 $0.07

2.0000 sec 2.0000 sec $0.00 $0.02

- - - - -

G-FOAM FILTER, LARGE, BOOSTER 5.0000 sec 5.0000 sec $0.12 $0.05

2.0000 sec 2.0000 sec $0.00 $0.02

G-EXCLUDER, BOOSTER 6.0000 sec 6.0000 sec - $0.06

0.0000 sec 0.0000 sec $0.00 $0.00

G-EXCLUDER, BOOSTER, Material 0.0000 sec 2.4700 sec $0.05 $0.01

- - - - -

- - - - -

- - - - -

G-CLEVIS LOCK NUT, BOOSTER 6.0000 sec 6.0000 sec $0.04 $0.06

7.0000 sec 7.0000 sec $0.00 $0.07

G-CLEVIS TO PEDAL 8.0000 sec 8.0000 sec - $0.08

0.0000 sec 0.0000 sec $0.00 $0.00

G-CLEVIS TO PEDAL-Machined 3.0000 sec 3.0000 sec - $0.01

- - - - -

- - - - -

0.0000 sec 0.0000 sec $0.00 $0.00

G-CLEVIS TO PEDAL-Stamped3.0000 sec 3.0000 sec - $0.03

0.0000 sec 0.0000 sec $0.00 $0.00

0.0000 sec 0.0000 sec $0.00 $0.00

G-CLEVIS TO PEDAL, Material 0.0000 sec 0.7000 sec $0.07 $0.00

- - - - -

- - - - -

- - - - -

3.0000 sec 3.0000 sec $0.00 $0.03

3.0000 sec 3.0000 sec $0.00 $0.03

5.0000 sec 5.0000 sec $0.00 $0.04

1.0000 sec 1.0000 sec $0.00 $0.01
2.0000 sec 2.0000 sec $0.00 $0.02

3.0000 sec 3.0000 sec $0.00 $0.01

5.0000 sec 5.0000 sec $0.00 $0.01

2.0000 sec 2.0000 sec $0.00 $0.01

7.0000 sec 7.0000 sec $0.00 $0.07

3.0000 sec 3.0000 sec $0.00 $0.03

4.0000 sec 4.0000 sec $0.00 $0.04

G Master Cylinder Asm 4.0000 sec 4.0000 sec $0.00 $0.04

0.0000 sec 0.0000 sec $0.00 $0.00

G Nut, Cylinder to Booster 6.0000 sec 6.0000 sec $0.04 $0.06

4.0000 sec 4.0000 sec $0.00 $0.04

4.0000 sec 4.0000 sec $0.00 $0.04

2.0000 sec 2.0000 sec $0.00 $0.02

3.0000 sec 3.0000 sec $0.00 $0.03

G Vacuum Hose, Booster 4.0000 sec 4.0000 sec $0.00 $0.04

0.0000 sec 0.0000 sec $0.00 $0.00

- - - - -

3.0000 sec 3.0000 sec $0.00 $0.03

3.0000 sec 3.0000 sec $0.00 $0.03

2.0000 sec 2.0000 sec $0.00 $0.02

2.0000 sec 2.0000 sec $0.00 $0.02

3.0000 sec 3.0000 sec $0.00 $0.03

Page 2 of 3

Number Munro Actual Time Piece Cost Total Labor 

Score Cost

Count: 395



Page 3 of 3
Qty Piece Cost Total Labor Cost 

(Total) (Total) (Total)

1 $0.00 $0.00

1 - $0.06

1 $0.00 $0.00

1 - $0.05

1 $0.00 $0.00

- - -

1 - $0.04

1 $0.00 $0.00

- - -

1 - $0.02

1 $0.00 $0.00

1 $1.03 $0.22

- - -

- - -

- - -

1 $0.00 $0.02

1 $0.00 $0.03

1 $0.00 $0.01

1 $0.00 $0.04

1 $0.00 $0.06

1 $0.00 $0.02

- - -

1 - $0.06

1 $0.00 $0.00

1 $0.01 $0.01

- - -

- - -

- - -

1 $0.00 $0.02

1 - $0.05

1 $0.00 $0.00

1 $0.02 $0.01

- - -

- - -

- - -

1 $0.00 $0.02

1 $0.00 $0.03

1 $0.26 $0.06

1 $0.00 $0.01

1 - $0.07

1 $0.00 $0.00

1 - $0.01

1 $0.00 $0.00

1 $0.03 $0.00

- - -

- - -

- - -
1 $0.00 $0.01 1 $0.00 $0.01 1 $0.00 $0.01 1 - $0.05 1 $0.00 $0.00 1 - $0.03 1 $0.00 $0.00 1 - $0.01 1 $0.00 $0.00 1 - $0.02 1 $0.00 $0.00 1 $0.09 $0.00 - - - - - - - - - 1 $0.00 $0.03 1 $0.00 $0.02 - - - 1 $0.00 $0.01 1 $0.00 $0.01 1 $0.00 $0.02 - - - 1 $0.00 $0.01 1 $0.00 $0.02 1 $0.00 $0.02 - - - 1 $0.00 $0.01 1 $0.00 $0.01 1 $0.00 $0.01 - - - 1 $0.00 $0.01 1 $0.00 $0.01 1 $0.00 $0.03 1 $0.00 $0.01 1 $0.00 $0.01 1 $0.00 $0.01 1 $0.00 $0.01 1 $0.00 $0.01 1 $0.01 $0.06 1 - $0.06 1 $0.00 $0.00 1 - $0.01 1 $0.00 $0.00 - - - 1 $0.02 $0.00 - - - - - - - - - 1 $0.00 $0.01 1 $0.00 $0.02 1 $0.00 $0.01 - - - 1 $0.00 $0.06 1 $0.00 $0.01 - - - 1 $0.00 $0.06
1 $0.00 $0.01 1 $0.00 $0.02 - - - 1 $0.00 $0.02 1 $0.00 $0.06 1 $0.00 $0.01 1 $0.00 $0.01 1 $0.00 $0.01 1 $0.00 $0.01 1 $0.00 $0.06 1 $0.00 $0.01 1 $0.00 $0.02 1 - $0.08 1 $0.00 $0.00 1 - $0.02 1 $0.00 $0.00 - - - 1 - $0.03 1 $0.00 $0.00 1 - $0.06 1 $0.00 $0.00 1 - $0.02 1 $0.00 $0.00 1 $0.70 $0.22 - - - - - - - - - - - - 1 $0.00 $0.02 1 $0.00 $0.03 1 $0.00 $0.01 1 - $0.02 1 $0.00 $0.00 1 - $0.02 1 $0.00 $0.00 1 $0.13 $0.02 - - - - - - - - - - - - 1 $0.00 $0.02 1 $0.00 $0.03 1 $0.00 $0.01 2 $0.08 $0.07 2 $0.00 $0.07 1 $0.00 $0.03 1 $0.00 $0.05 1 $0.00 $0.02 - - - 1 - $0.06 1 $0.00 $0.00 1 $0.04 $0.01 - - - - - - - - - 1 $0.00 $0.02
1 $0.00 $0.03

2 - $0.14

2 $0.00 $0.00

- - -

2 $0.67 $0.10

2 $0.00 $0.06

2 $0.00 $0.02

2 $0.11 $0.08

2 $0.00 $0.04

1 - $0.10

1 $0.00 $0.00

1 - $0.07

1 $0.00 $0.00

1 - $0.05

1 $0.00 $0.00

1 $0.25 $1.31

- - -

- - -

- - -

1 - $0.07

1 $0.00 $0.00

- - -

- - -

1 - $0.05

- - -

1 $0.00 $0.00

1 - $0.01

- - -

1 $0.00 $0.00

- - -

1 $0.08 $0.00

- - -

- - -

1 $0.00 $0.02

1 $0.00 $0.02

1 $0.00 $0.01

1 $0.00 $0.03

Qty Piece Cost Total Labor Cost 

(Total) (Total) (Total)

1 $0.00 $0.03

1 $0.00 $0.01

1 $0.00 $0.02

1 $0.00 $0.02

1 $0.00 $0.01

1 $0.00 $0.03

1 $0.00 $0.01

1 $0.00 $0.01

1 $0.00 $0.01
-

--

---

---

1 $0.00 $0.01 1 $0.00 $0.01 1 $0.00 $0.01 1 - $0.03 1 $0.00 $0.00 1 $0.01 $0.00 - - - - - - - - - 1 $0.07 $0.04 1 - $0.02 1 $0.00 $0.00 1 $0.03 $0.00 - - - - - - - - - 1 $0.04 $0.04 1 - $0.02 1 $0.00 $0.00 - - - 1 $0.01 $0.00 - - - 1 $0.01 $0.02 - - - - - - - - - 1 $0.00 $0.03 1 - $0.05 1 $0.00 $0.00 1 - $0.01 1 $0.00 $0.00 1 $0.12 $0.00 - - - - - - - - - 1 $0.00 $0.02 1 $0.00 $0.02 1 $0.00 $0.01 1 $0.00 $0.03 1 $0.00 $0.01 1 $0.00 $0.03 1 $0.00 $0.03 1 $0.00 $0.03 1 $0.00 $0.01 1 $0.00 $0.03 1 $0.00 $0.01 1 $0.00 $0.01 1 $0.00 $0.02 1 $0.00 $0.02 1 $0.00 $0.01 1 $0.00 $0.01 - - - - - -
-

--

1 $0.00 $0.01 1 $0.00 $0.01 1 $0.00 $0.01 1 $0.00 $0.01 1 $0.00 $0.06 1 $0.00 $0.05 - - - 1 $0.06 $0.02 1 $0.00 $0.06 1 $0.00 $0.05 1 $0.00 $0.06 1 $0.00 $0.05 1 $0.00 $0.02 1 $0.00 $0.01 1 - $0.06 1 $0.00 $0.00 - - - 1 $0.01 $0.00 1 $0.00 $0.00 1 - $0.01 1 $0.00 $0.00 1 $0.08 $0.00 - - - - - - - - - - - - - - - - - - 1 $0.00 $0.02 1 $0.00 $0.03 1 - $0.05 1 $0.00 $0.00 1 $0.01 $0.04 - - - - - - - - - 1 $0.00 $0.03 - - - 1 $0.06 $0.05 1 $0.00 $0.02 1 $0.05 $0.05 1 $0.00 $0.02 1 - $0.07 1 $0.00 $0.00 - - - 1 - $0.02 1 $0.00 $0.00 1 $0.63 $0.02 - - - - - - - - - 1 $0.00 $0.02 1 $0.00 $0.03 1 $0.00 $0.01 1 $0.00 $0.01
1 $0.00 $0.06 4 $0.00 $0.16 4 $0.00 $0.04 1 - $0.10 1 $0.00 $0.00 1 $0.30 $0.08 - - - - - - - - - 1 $0.00 $0.02 1 $0.00 $0.06 1 $0.00 $0.05 1 $0.00 $0.03 2 - $0.12 2 $0.00 $0.00 2 $0.13 $0.12 2 $0.00 $0.06 2 $0.00 $0.02 2 $0.11 $0.08 2 $0.00 $0.04 2 $0.00 $0.14 1 $0.00 $0.02 1 $0.00 $0.00 6 $0.00 $0.06 1 $0.00 $0.03 - - - 1 $0.06 $0.07 1 $0.00 $0.02 - - - 1 $0.12 $0.05 1 $0.00 $0.02 1 - $0.06 1 $0.00 $0.00 1 $0.05 $0.01 - - - - - - - - - 1 $0.04 $0.06 1 $0.00 $0.07 1 - $0.08 1 $0.00 $0.00 1 - $0.01 - - - - - - 1 $0.00 $0.00 1 - $0.03 1 $0.00 $0.00 1 $0.00 $0.00 1 $0.07 $0.00 - - - - - - - - - 1 $0.00 $0.03 1 $0.00 $0.03 1 $0.00 $0.04 1 $0.00 $0.01
1 $0.00 $0.02

1 $0.00 $0.01

1 $0.00 $0.01

1 $0.00 $0.01

1 $0.00 $0.07

1 $0.00 $0.03

1 $0.00 $0.04

1 $0.00 $0.04

1 $0.00 $0.00

2 $0.07 $0.12

1 $0.00 $0.04

2 $0.00 $0.08

1 $0.00 $0.02

2 $0.00 $0.06

1 $0.00 $0.04

1 $0.00 $0.00

- - -

1 $0.00 $0.03

1 $0.00 $0.03

1 $0.00 $0.02

1 $0.00 $0.02

1 $0.00 $0.03

Qty Piece Cost Total Labor Cost 

(Total) (Total) (Total)

323 $5.66 $9.20




Includes Tier1I/OEM markup Used: T1 Moderate Assembly Complexity

Assumed returnable dunnage - no dividers Used: Returnable Dunnage

Input Rod Assembly - material PET-GF36 not in RM database -Used Lean Design ~$1.20/lb (See Input Rod assembly tab)
G Brake Booster Assembly, Populated Part # QTY $$$

x G BRAKE BOOSTER ASSEMBLY 1 0.96

x G NUT, CYLINDER TO BOOSTER 2 0.16

G MASTER CYLINDER ASM 1

x G VACUUM HOSE, BOOSTER 1 1.30

x G BRAKE BOOSTER 1 1.91

x G FRONT SHELL, BRAKE BOOSTER 1 1.79

x G LABEL, FRONT SHELL, BRAKE BOOSTER 1 0.12

x G-VAC HOSE SEAL FRNT SHELL 1 0.10

x G-VAC HOSE FITTING FRNT SHELL 1 0.10

x G-SPRING LARGE, BRAKE BOOSTER 1 0.52

x G-RETAINER, OUTPUT ROD 1 0.15

x G FOAM SEAL, REAR SHELL 1 0.11

x G-FOAM FILTER, LARGE, BOOSTER 1 0.15

x G-EXCLUDER, BOOSTER 1 0.14

x G-CLEVIS LOCK NUT, BOOSTER 1 0.06

x G-CLEVIS TO PEDAL 1 0.67

x A G OUTPUT ROD ASM 1 0.19

x G ROD, OUTPUT 1 0.94

x G WASHER, OUTPUT ROD, 1.00 MM 1 0.01

x G SOCKET,OUTPUT ROD 1 0.48

x B G-REAR ASSEMBLY 1 1.57

x G-VACUUM SEAL REAR SHELL 1 0.08

x B1 G SHELL REAR W/STUDS, BOOSTER 1 0.25

x G-SHELL REAR BOOSTER 1 1.30

x G-SHELL REAR STUD PLATE, BOOSTER 1 0.38

x G STUD, REAR SHELL 2 0.09

x B2 G-TIE RODS W/O-RINGS, BOOSTER 2 0.12

x G-TIE ROD, BRAKE BOOSTER 2 0.77

x G-O-RING, TIE ROD, BOOSTER 2 0.13

x B3 G-NUT W/ORING BOOSTER 1 0.12

x G-NUT, TIE ROD ADJUSTER 2 0.15

x G-O-RING, TIE ROD, BOOSTER 2 0.13

x B4 G-CENTER ASSEMBLY, BOOSTER 1 1.04

x G-CENTER PLATE, BOOSTER 1 0.88

x G-DIAPHRAGM, BOOSTER 1 0.62

x B4A G-VALVE BODY ASY BODY 1 0.96

x G-BODY, VALVE BOOSTER 1 0.54

x G-DISK, REACTION, BOOSTER-MOLDING 1 0.19

x GREEN FOAM FILTER VALVE BODY 1 0.07

x G-FOAM FILTER, YELLOW, VALVE BODY, 1 0.06

x B4A1 G-INPUT ROD ASY 1 0.89

x G-INPUT ROD, VALVE BODY 1 0.67

x G-RETAINER, INPUT ROD SPRING 1 0.05

x G- SPRING, INPUT ROD, VALVE BODY 1 0.08

x G-RETAINER, POPET SPRING 1 0.03

x G-SPRING, POPET, VALVE BODY 1 0.05
x G-WASHER, POPPET, VALVE BODY

1 0.02

x G-POPPET, VALVE BODY1 0.15

x G-PLUNGER, VALVE BODY1 0.84

x SEAL, POPPET VALVE1 0.07

x B4A2 G- KEY, BOOSTER1

x G-KEY BOOSTER, MATE1 0.12

x G- KEY, BOOSTER, METAL1 0.10

60 22.38
Comments

?? Hybrid 2@.07

Beyond Scope

Commodity Pricing ? Scaled from H spring

Same as H

Commodity Pricing ?

Commodity Pricing

Same as H

Commodity Pricing

15

Commodity Pricing

Commodity Pricing

Commodity Pricing

Commodity Pricing

Commodity Pricing Same as H

Commodity Pricing

Commodity Pricing

Commodity Pricing
Commodity Pricing Same as H H shows $0.02 used that amount

Commodity Pricing Same as H

Overmold Same as H
Page:1 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

Scrap SG&A Profit ED&T-R&D

0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

07 Power Brake Subsystem (for Hydraulic)

1 00 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Assembly of Power Brake Subsystem Components

2 01 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

A H Brake Booster Assembly Populated 06 07 01 - B0502 - 01 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

A1 Brake Booster Assembly (Master Cylinder Removed) 06 07 01 - B0502 - 02 $ 6.30 $ 6.24 $ 4.87 $ 17.40 $ 0.09 $ 1.24 $ 1.12 $ 0.44 $ 2.89 $ - $ 20.30

B1 H Nut, Cylinder to Booster 06 07 01 - B0502 - 03 Same Base and HEV - Commodity $ 0.14 $ - $ - $ - $ - $ 0.01 $ 0.01 $ 0.02 $ 0.16 $ - $ 0.16

System 

ED&T/R&D

(x1000)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Assembly

Name/Description Part Number

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly of Power Brake Subsystem (for Hydraulic)

Vacuum Booster

Subassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft

Technology Level: Electrical Versus Mechanical Brake Booster Assembly

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: N0502 (N=New, B=Base, ) 05=Technology Package, 02=Vehicle Class

Technology Level: Parallel HEV Technology

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: N0502 (N=New, B=Base, ) 05=Technology Package, 02=Vehicle Class

3 02

A H Vacuum Pump Assembly

4 03 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

5 04 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

6 07 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

7 10 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 60 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A Wire Harness Connector - Vacuum Sensor Brake Booster

B Wire Harness - Vacuum Solenoid, Brake Booster

C Wire Harness - Booster Travel Sensor 

9 70 $ 0.65 $ 0.23 $ 0.21 $ 1.09 $ 0.01 $ 0.10 $ 0.09 $ 0.03 $ 0.23 $ 0.02 $ 1.34 $ -

A H Vacuum Hose Assembly , Booster 06 07 70 - B0502 - 01 $ 0.65 $ 0.23 $ 0.21 $ 1.09 $ 0.01 $ 0.10 $ 0.09 $ 0.03 $ 0.23 $ 0.02 $ 1.34

10 75 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Hydraulic Booster

Vacuum Reservoir and Distribution Components

Vacuum Pump and Motor

TBD

Pipes, Hoses, Ducting

TBD

Wire Harness Connections

Brackets

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:2 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

Scrap SG&A Profit ED&T-R&D

System 

ED&T/R&D

(x1000)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Assembly

Name/Description Part Number

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Subassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft

Technology Level: Electrical Versus Mechanical Brake Booster Assembly

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: N0502 (N=New, B=Base, ) 05=Technology Package, 02=Vehicle Class

Technology Level: Parallel HEV Technology

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: N0502 (N=New, B=Base, ) 05=Technology Package, 02=Vehicle Class

11 80 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A H Bolt Vacuum Pump to Block

B H Nut Vacuum Pump to Block

C

D

12 85 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 90 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Boltings

Sealing Elements

13 90 Bearings Elements Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 99 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

Miscellaneous

Bearings Elements Misc

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:3 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

07 Power Brake Subsystem (for Hydraulic)

1 00

Assembly of Power Brake Subsystem Components

2 01

A H Brake Booster Assembly Populated 06 07 01 - B0502 - 01

A1 Brake Booster Assembly (Master Cylinder Removed) 06 07 01 - B0502 - 02

B1 H Nut, Cylinder to Booster 06 07 01 - B0502 - 03 Same Base and HEV - Commodity

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

A

(Default =1) ssembly

Name/Description Part Number

Item

Subsystem

QTY/ Subsystem

Notes

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly of Power Brake Subsystem (for Hydraulic)

Vacuum Booster

Subassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft

Technology Level: Electrical Versus Mechanical Brake Booster Assembly

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: N0502 (N=New, B=Base, ) 05=Technology Package, 02=Vehicle Class

Technology Level: Parallel HEV Technology

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: N0502 (N=New, B=Base, ) 05=Technology Package, 02=Vehicle Class

$ - $ -

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

3 02

A H Vacuum Pump Assembly

4 03

5 04

6 07

7 10

8 60

A Wire Harness Connector - Vacuum Sensor Brake Booster

B Wire Harness - Vacuum Solenoid, Brake Booster

C Wire Harness - Booster Travel Sensor 

9 70

A H Vacuum Hose Assembly , Booster 06 07 70 - B0502 - 01

10 75

Hydraulic Booster

Vacuum Reservoir and Distribution Components

Vacuum Pump and Motor

TBD

Pipes, Hoses, Ducting

TBD

Wire Harness Connections

Brackets

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:4 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

A

(Default =1) ssembly

Name/Description Part Number

Item

Subsystem

QTY/ Subsystem

Notes

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Subassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft

Technology Level: Electrical Versus Mechanical Brake Booster Assembly

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: N0502 (N=New, B=Base, ) 05=Technology Package, 02=Vehicle Class

Technology Level: Parallel HEV Technology

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: N0502 (N=New, B=Base, ) 05=Technology Package, 02=Vehicle Class

11 80

A H Bolt Vacuum Pump to Block

B H Nut Vacuum Pump to Block

C

D

12 85

13 90

Boltings

Sealing Elements

Bearings Elements Misc

Investment

(X1000)

Tooling 

(x1000)

$ - $ -

$ - $ -

13 90 $ - $ -

14 99

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

Miscellaneous

Bearings Elements Misc $ - $ -

$ - $ -

$ - $ -

09000064810ec171.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Author: G. Kolwich

(248)373-6000 Ext. 2411