INSTRUCTIONS

The Department requests costing and efficiency data for residential dishwashers based on an efficiency level approach. The Department seeks the average incremental production cost to take basic models 

in the categories shown to the specified design option or efficiency level. For those product classes where more than one basic model may exist, please indicate the minimum and maximum incremental costs 

that would be incurred across the array of basic models.

Shipments

The AHAM 2005 Fact Book offers historical shipments and efficiency data, but not disaggregated by the product classes that the Department is considering. As shown in the ‘shipment request’ tables for 

residential dishwashers, the Department hopes to collect both shipments data and shipment-weighted average efficiency data dating back to 1990. In addition, the Department hopes to collect market share 

efficiency (i.e., data on the distribution of product shipments by efficiency) for each product class. 

Energy and Water Use

The Department seeks detailed energy and water use data from manufacturers for the energy efficiency levels that it will analyze in the engineering analysis.

Manufacturer Costs 

Incremental cost data (in U.S. dollars) includes the materials, labor, and overhead needed to take basic models to each higher efficiency level. The depreciation of the conversion capital expenditures is an 

important component of the manufacturer costs for the Department to understand to evaluate manufacturer impacts. The Department is therefore requesting detailed information about conversion capital 

expenditures and depreciation by efficiency level.

Please review the exploratory efficiency levels in the first table and complete the following tables to the best of your ability. For each manufacturer cost data table, please assume mass 

production at each efficiency level. Definitions for manufacturing cost terminology are provided below. 

Direct material – Costs of raw materials including scrap that can be traced to final or end products. Direct material costs do not include indirect material 

costs which are attributed to supplies that may be used in the production process but are not assigned to final products (e.g., lubricating oil for production 

machinery).

Direct labor – The earnings of workers who assemble parts into a finished good for operate machines in the production process. Direct labor includes the 

Full Production Cost = Direct Material + Direct Labor + Overhead (factory) + Depreciation

Full Cost of Product = Full Production Cost + Non-production Costs (SG&A, ordinary R&D, interest, and profit)

Non-production costs are estimated by the Department using a manufacturer markup that is derived through industry financial statement analysis.

machinery).

Direct labor – The earnings of workers who assemble parts into a finished good for operate machines in the production process. Direct labor includes the 

fringe benefits of direct laborers such as group health care, as well as overtime pay. Direct labor does not include indirect labor which is defined as the 

earnings of employees who do not work directly in assembling a product, such as supervisors, janitors, stockroom personnel, inspectors, and forklift 

operators.

Overhead – Factory overhead excluding depreciation. Factory overhead includes indirect labor, downtime, set-up costs, indirect material, expendable 

tools, maintenance, property taxes, insurance on assets, and utility costs. Factory overhead does not include selling, general, and administrative costs 

(SG&A); research and development (R&D); interest; or profit (accounted for by the Department separately).

(Depreciation on) conversion capital expenditures – Conversion capital expenditures are one-time investments in property, plant, and equipment to 

adapt or change existing production facilities so that new product designs can be fabricated and assembled under the new regulation. The Department 

requests the incremental depreciation associated with these expenditures. Depreciation is a noncash expense that reduces the value of an asset as a 

result of wear and tear, age, or obsolescence.

Product conversion expense – Product conversion expenses are one-time investments in R&D, testing, and marketing focused on making product 

designs comply with the new efficiency standard. GRIM allocates these costs over the period between the standard’s announcement and effective dates. 

These are expenses that will be taken into account in the MIA. They will not be used in the engineering analysis or LCC and payback period analysis.
Table 1 Exploratory Efficiency Levels for Dishwasher Analysis

Compact

baseline DOE Standard 260 kWh, 4.5 gal/cycle

1 ENERGY STAR (current) 234 kWh, 4.0 gal/cycle

2

ENERGY STAR (July 1, 

2011)/CEE Tier 1 222 kWh, 3.5 gal/cycle

3

Gap Fill (Compact)*/CEE 

Tier 2 (Standard) 200 kWh, 2.8 gal/cycle

4 Gap Fill* 174 kWh, 2.7 gal/cycle

5 Max Available* 154 kWh, 2.1 gal/cycle

* Source: ENERGY STAR qualified dishwashers as of January 30, 2011.

PLEASE COMPLETE

Table 2 Dishwasher Shipment and Shipment-Weighted Average Efficiency Data

Shipment-Weighted 

Average Energy Use 

(kwh/cycle)

Shipment-Weighted Average 

Annual Energy Use

(AEU) 

Portable Built In Total Industry Total Industry 

1990 2.67

1991 2.67

1992 2.66

1993 2.56

1994 2.14

1995 2.07

1996 2.06

1997 2.02

1998 1.97

1999 1.98

2000 164,425 5,663,253 2.00

2001 149,372 5,478,001 1.92

2002 158,131 6,048,661 1.84

2003 148,092 6,280,259 1.83

2004 152,968 6,952,543 1.68

2005 133,204 7,290,992 1.67

2006 129,777 7,121,727 1.63

2007 110,213 6,866,617 1.53

2008 91,693 5,903,431 1.52

2009 70,278 5,333,374 1.45

Level Efficiency Level Source Annual Energy Use/Water Use

Year

Shipments, Domestic + Imports

(Thousands of Units)
2010 65,544 5,644,862 1.37

PLEASE COMPLETE

Table 3 Standard Dishwasher Market Share Efficiency Data 

2007 2008 2009 2010

Baseline: 325 - 355 kWh 51.2% 37.3% 3.8%

Level 1: 308 - 324 kWh 27.2% 39.7% 51.7%

Level 2: 296 - 307 kWh 7.1% 8.6% 21.5%

Level 3: 235 - 295 kWh 5.3%* 10.8% 22.8%*

Level 4: 181 - 234 kWh n/a n/a n/a

Level 5: <= 180 kWh 0.0% n/a n/a

*includes levels 3&4 *includes levels 3, 4 & 5 *includes levels 3, 4 & 5

Table 3 Compact Dishwasher Market Share Efficiency Data - NOT ENOUGH DATA TO REPORT

2007 2008 2009 2010

Baseline: 235 - 260 kWh

Level 1: 223 - 234 kWh

Level 2: 201 - 222 kWh

Level 3: 175 - 200 kWh

Level 4: 155 - 174 kWh

Level 5: 154 kWh

PLEASE COMPLETE

Table 4A Energy and Water Use Data for Standard Dishwashers (2009)- AVG per LEVEL (Range)

Standby Water Use

Annual Energy Use Efficiency 

Level (AEU) Hot Water (kWh/cycle) Machine (kWh/cycle) Standby Power (W) (gallons/ cycle)

Baseline = 355 kWh/yr 4.84

Level 1 = 324 kWh/yr 4.38

Level 2 = 307 kWh/yr 5.09

Level 3 = 295 kWh/yr 4.7

Level 4 = 234 kWh/yr 2.7

Level 5 = 180 kWh/yr 2.63

PLEASE COMPLETE

Table 4B Energy and Water Use Data for Compact Dishwashers - NOT ENOUGH DATA TO REPORT

Standby Water Use

Annual Energy Use Efficiency 

Level (AEU) Hot Water (kWh/cycle) Machine (kWh/cycle) Standby Power (W) (gallons/ cycle)

Market Share (percent)

Market Share (percent) Efficiency Bins (Annual Energy 

Use)

Efficiency Bins (Annual Energy 

Use)

Total Energy Use Breakdown (%)

Total Energy Use Breakdown (%)
Baseline = 260 kWh/yr

Level 1 = 234 kWh/yr

Level 2 = 222 kWh/yr

Level 3 = 200 kWh/yr

Level 4 = 174 kWh/yr

Level 5 = 154 kWh/yr

PLEASE COMPLETE

Table 5A Standard Dishwasher Manufacturer Cost Data

Product Class

Efficiency Level 1 2 3 4 5

Annual Energy Use 324 kWh/yr 307 kWh/yr 295 kWh/yr 234 kWh/yr 180 kWh/yr

Direct Material

Direct Labor

Overhead excluding depreciation

Direct Material

Direct Labor

Overhead excluding depreciation

Direct Material

Direct Labor

Overhead excluding depreciation

Building Depreciation

Tooling/ Equip Depreciation

R&D

Marketing

* Incremental costs per unit should be reported relative to the baseline unit’s cost. The baseline unit complies with the federal standard for residential dishwashers and is equal to 355 kWh/yr for standa

Table 5B Compact Dishwasher Manufacturer Cost Data

Product Class

Efficiency Level 1 2 3 4 5

Annual Energy Use 234 kWh 222 kWh 200 kWh 174 kWh 154 kWh

Direct Material

Direct Labor

Overhead excluding depreciation

Minimum Incremental Costs ($ Per Unit)*

Maximum Incremental Costs ($ Per Unit)*

Incremental Depreciation (on conversion capital) ($ Per Unit)

One-Time Product Conversion Expenses ($, Millions)

Compact Dishwashers

Average Incremental Costs ($ Per Unit)*

Standard Dishwashers

Average Incremental Costs ($ Per Unit)*

Minimum Incremental Costs ($ Per Unit)*
Direct Material

Direct Labor

Overhead excluding depreciation

Direct Material

Direct Labor

Overhead excluding depreciation

Building Depreciation

Tooling/ Equip Depreciation

R&D

Marketing

* Incremental costs per unit should be reported relative to the baseline unit’s cost. The baseline unit complies with the federal standard for residential dishwashers and is equal to 260 kWh/yr for compa

PLEASE COMPLETE

Table 6A Standard Dishwasher Depreciation Assumptions Used to Calculate Per Unit Incremental Depreciation in Table 5A

Product Class

Efficiency Level 1 2 3 4 5

Annual Energy Use 324 kWh/yr 307 kWh/yr 295 kWh/yr 234 kWh/yr 180 kWh/yr

Building

Tooling/Equipment

Building

Tooling/Equipment

Table 6B Compact Dishwasher Depreciation Assumptions Used to Calculate Per Unit Incremental Depreciation in Table 5B

Product Class

Efficiency Level 1 2 3 4 5

Annual Energy Use 234 kWh 222 kWh 200 kWh 174 kWh 154 kWh

Building

Tooling/Equipment

Building

Tooling/Equipment

Compact Dishwashers

Conversion Capital Expenditure Assumption ($, Millions)

Units Shipped

Depreciation Lifetimes (years)

Maximum Incremental Costs ($ Per Unit)*

Incremental Depreciation (on conversion capital) ($ Per Unit)

One-Time Product Conversion Expenses ($, Millions)

Standard Dishwashers

Conversion Capital Expenditure Assumption ($, Millions)

Units Shipped

Depreciation Lifetimes (years)


d is equal to 355 kWh/yr for standard dishwashers.
d is equal to 260 kWh/yr for compact dishwashers.