**INSTRUCTIONS** The Department requests costing and efficiency data for residential dishwashers based on an efficiency level approach. The D epa rtment 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 ba sic 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 th e D epartment is considering. As shown in the ‘shipment request’ tables for residential dishwashers, the Department hopes to collect both shipments data and shipment
- we ighted average efficiency data datin g 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 anal yze 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 highe r e fficiency 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 Departm ent 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 abil**  **ity . 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 ind irect 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 stat ement 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 indirec t l abor which is defined as the earnings of employees who do not work directly in assembling a product, such as supervisors, janitors, stockroom personnel, i nsp ectors, 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 regu lat ion. The Department requests the incremental depreciation associated with these expenditures. Depreciation is a noncash expense that reduces the va lue 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 announcem ent 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 pay back period analysis.

### Table 1 Exploratory **Efficiency**

**Levels for Dishwasher Analy sis**  **Compact** baseline DOE Standard 260 kW h, 4.5 gal/cycle 1 ENERGY STAR (current) 234 kW h, 4.0 gal/cycle 2 ENERGY STAR (July 1,

2011)/CEE Tier 1 222 kW h, 3.5 gal/cycle
3 Gap Fill (Compact)*/CEE

Tier 2 (Standard) 200 kW h, 2.8 gal/cycle 4 Gap Fill* 174 kW h, 2.7 gal/cycle 5 Max Available* 154 kW h, 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/cy cle)**  **Shipment-Weighted A verage**  **An nual Energy Use**  **(A EU)**  **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**  **An nual 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 kW h 51.2% 37.3% 3.8% Level 1: 308 - 324 kW h 27.2% 39.7% 51.7% Level 2: 296 - 307 kW h 7.1% 8.6% 21.5% Level 3: 235 - 295 kW h 5.3%* 10.8% 22.8%* Level 4: 181 - 234 kW h n/a n/a n/a Level 5: <= 180 kW h 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 kW h Level 1: 223 - 234 kW h Level 2: 201 - 222 kW h Level 3: 175 - 200 kW h Level 4: 155 - 174 kW h Level 5: 154 kW h 

### PLEASE COMPLETE **Table 4A Energy**

**and Water Use Data for Standard Dishwashers (2009)- AVG per LEVEL (Range)**  **Standby Water Use**  **An nual Energy Use Efficiency** 

**Level (A EU)**  **Hot Water (kWh/cy cle)**  **Machine (kWh/cy cle)**  **Standby Power (W)**  **(gallons/ cy cle)**  Baseline = 355 kW h/yr 4.84 Level 1 = 324 kW h/yr 4.38 Level 2 = 307 kW h/yr 5.09 Level 3 = 295 kW h/yr 4.7 Level 4 = 234 kW h/yr 2.7 Level 5 = 180 kW h/yr 2.63 

### PLEASE COMPLETE **Table 4B Energy**

**and Water Use Data for Compact Dishwashers - NOT ENOUGH DATA TO REPORT**  **Standby Water Use**  **An nual Energy Use Efficiency** 

**Level (A EU)**  **Hot Water (kWh/cy cle)**  **Machine (kWh/cy cle)**  **Standby Power (W)**  **(gallons/ cy cle)**  **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 kW h/yr Level 1 = 234 kW h/yr Level 2 = 222 kW h/yr Level 3 = 200 kW h/yr Level 4 = 174 kW h/yr Level 5 = 154 kW h/yr


### PLEASE COMPLETE **Table 5A Standard Dishwasher Manufacturer Cost Data Product Class**  Efficiency Level 1 2 3 4 5 Annual Energy Use 324 kW h/yr 307 kW h/yr 295 kW h/yr 234 kW h/yr 180 kW h/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 w ith the federal standard for residential dishwashers and is equal to 355 kW h/yr for standard dishwashers. 

### Table 5B Compact Dishwasher Manufacturer Cost Data **Product Class** Efficiency Level 1 2 3 4 5 Annual Energy Use 234 kW h 222 kW h 200 kW h 174 kW h 154 kW h 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 w ith the federal standard for residential dishwashers and is equal to 260 kW h/yr for compact dishwashers. 

### 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 kW h/yr 307 kW h/yr 295 kW h/yr 234 kW h/yr 180 kW h/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 kW h 222 kW h 200 kW h 174 kW h 154 kW h Building Tooling/Equipment

Building Tooling/Equipment **Compact Dishwashers**
**Conversion Capital Expenditure A ssumption ($, Millions)** 
**Units Shipped Depreciation Lifetimes (years)**  **Maximum Incremental Costs ($ Per Unit)***

**Incremental Depreciation (on conversion capital) ($ Per Unit) One-Time Product Conversion Expenses ($, Millions)** 

**Standard Dishwashers**
**Conversion Capital Expenditure A ssumption ($, Millions)** 
**Units Shipped Depreciation Lifetimes (years)** Incremental costs per unit should be reported relative to the baseline unit’s cost. The baseline unit complies w ith the federal standard for residential dishwashers and is equal to 355 kW h/yr for standard dishwashers.Incremental costs per unit should be reported relative to the baseline unit’s cost. The baseline unit complies w ith the federal standard for residential dishwashers and is equal to 260 kW h/yr for compact dishwashers.