Page:1 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

180600 Traction And High Voltage Power Distribution Subsystem

1 00 Assembly of H Traction & HV Power Distribution Subsystem $ 1.41 $ 7.58 $ 2.63 $ 11.62 $ - $ - $ - $ - $ - $ - $ 11.62 Negligible Difference

Calculated cost based on wire length 

change and peak current discharging Wire pricing per 5.49mm dia. = $2.13/foot 

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATIO

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Scaling Parameter(s) Description Notes

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 HV Voltage Wire Harness & Connectors $ 121.81 $ 22.71 $ 11.56 $ 156.07 $ 0.78 $ 10.14 $ 9.36 $ 3.90 $ 24.19 $ 0.57 $ 180.84 change and peak current discharging 

differences between specific application and 

Ford Fusion HEV baseline.

and 2.72mm dia. = 0.76/ft

Baseline Harness Length 25.5 ft 

3 02 HV External Protective Coverings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

4 03 HV Cable Grommet Assembly $ 0.30 $ 0.01 $ 0.11 $ 0.42 $ 0.00 $ 0.02 $ 0.02 $ 0.00 $ 0.05 $ 0.01 $ 0.47 Negligible Difference

5 75 Brackets $ 1.34 $ 1.24 $ 1.47 $ 4.05 $ 0.01 $ 0.24 $ 0.16 $ 0.04 $ 0.46 $ 0.07 $ 4.58 Negligible Difference

6 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

7 80 BIW Fasteners for HV Wire Harness Mounting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 99 Miscellaneous $ 2.15 $ 0.89 $ 0.39 $ 3.43 $ 0.02 $ 0.22 $ 0.21 $ 0.09 $ 0.53 $ 0.03 $ 3.99 Negligible Difference

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:2 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATIO

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Scaling Parameter(s) Description Notes

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)

SUBSYSTEM ROLL-UP $ 127.00 $ 32.43 $ 16.16 $ 175.58 $ 0.81 $ 10.64 $ 9.75 $ 4.03 $ 25.23 $ 0.68 $ 201.50 $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:3 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATIO

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Scaling Parameter(s) Description Notes

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)

Material Labor Burden End Item 

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

05 Cylinder Blocks

A1 01 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B1 02 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

C1 03 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Markup

BASE 

TECHNO

LOGY 

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

BASE TECHNOLOGY PACKAGE COST INFORMAT

Item

Subsystem

Sub-Subsystem

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

D1 04 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:4 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATIO

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Scaling Parameter(s) Description Notes

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 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

E1 65 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

F1 66 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

G1 67 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

H1 70 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ $ - $ $ - $ - $ $ - $ - $ - $ - $ - $ $ - $ $ - $ $ -

I1 75 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

J1 80 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

K1 85 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

L1 90 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

M1 99 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

N1 00 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SU

BS

YS

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

Material Labor Burden End Item 

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

05 Cylinder Blocks

TECHNO

LOGY 

PACKAG

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOG

Item

Subsystem

Sub-Subsystem

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

A1 01 $ 1.41 $ 7.58 $ 2.63 $ 11.62 $ - $ - $ - $ - $ - $ - $ 11.62

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:5 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATIO

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Scaling Parameter(s) Description Notes

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)

B1 02 $ 121.81 $ 22.71 $ 11.56 $ 156.07 $ 0.78 $ 10.14 $ 9.36 $ 3.90 $ 24.19 $ 0.57 $ 180.84

C1 03 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

D1 04 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

E1 65 $ 1.34 $ 1.24 $ 1.47 $ 4.05 $ 0.01 $ 0.24 $ 0.16 $ 0.04 $ 0.46 $ 0.07 $ 4.58

F1 66 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

G1 67 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

H1 70 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

I1 75 $ 2.15 $ 0.89 $ 0.39 $ 3.43 $ 0.02 $ 0.22 $ 0.21 $ 0.09 $ 0.53 $ 0.03 $ 3.99

J1 80 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

K1 85 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

L1 90 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

M1 99 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

N1 00 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SU

BS

YS

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:6 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

180600 Traction And High Voltage Power Distribution Subsystem

1 00

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value Material Labor Burden End Item 

Scrap SG&A Profit 

1.00 $ 11.62 1.00 $ 11.62 1.00 $ 11.62 1.00 $ 11.62 1.00 $ 11.62 1.00 $ 11.62 $ - $ - $ - $ - $ - $ - $ -

BASE TECHNOLOGY GENERAL PAR

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

EW TECHNOLOGY GENERAL PART INFORMATION:

0 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

0kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

Small/Compact Vehicle Segment 

Passenger 2-5

(e.g. Ford Focus)

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

2 01

3 02

4 03

5 75

6 80

7 80

8 85

9 99

Multi $ 176.45 Multi $ 180.57 Multi $ 182.62 Multi $ 183.31 Multi $ 180.57 Multi $ 191.54 $ - $ - $ - $ - $ - $ - $ -

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

1.00 $ 0.47 1.00 $ 0.47 1.00 $ 0.47 1.00 $ 0.47 1.00 $ 0.47 1.00 $ 0.47 $ - $ - $ - $ - $ - $ - $ -

1.00 $ 4.58 1.00 $ 4.58 1.00 $ 4.58 1.00 $ 4.58 1.00 $ 4.58 1.00 $ 4.58 $ - $ - $ - $ - $ - $ - $ -

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

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

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

1.00 $ 3.99 1.00 $ 3.99 1.00 $ 3.99 1.00 $ 3.99 1.00 $ 3.99 1.00 $ 3.99 $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:7 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value Material Labor Burden End Item 

Scrap SG&A Profit 

BASE TECHNOLOGY GENERAL PAR

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

EW TECHNOLOGY GENERAL PART INFORMATION:

0 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

0kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

Small/Compact Vehicle Segment 

Passenger 2-5

(e.g. Ford Focus)

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

$ 197.11 $ 201.22 $ 203.28 $ 203.97 $ 201.22 $ 212.20 $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:8 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value Material Labor Burden End Item 

Scrap SG&A Profit 

BASE TECHNOLOGY GENERAL PAR

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

EW TECHNOLOGY GENERAL PART INFORMATION:

0 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

0kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

Small/Compact Vehicle Segment 

Passenger 2-5

(e.g. Ford Focus)

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

05 Cylinder Blocks

A1 01

2

B1 02

2

C1 03

2

BASE 

TECHNO

LOGY 

Item

Subsystem

Sub-Subsystem

Material Labor Burden End Item 

Scrap SG&A Profit 

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

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

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

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

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

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

BASE TECHNOLOGY PACKAGE COS

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

ASE TECHNOLOGY PACKAGE COST INFORMATION

2

D1 04

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

#REF! #REF! #REF! #REF! #REF! #REF! #REF!

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:9 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

2

E1 65

2

F1 66

2

G1 67

2

H1 70

2

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value Material Labor Burden End Item 

Scrap SG&A Profit 

BASE TECHNOLOGY GENERAL PAR

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

EW TECHNOLOGY GENERAL PART INFORMATION:

0 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

0kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

Small/Compact Vehicle Segment 

Passenger 2-5

(e.g. Ford Focus)

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

#REF! #REF! #REF! #REF! #REF! #REF! #REF!

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

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

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

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

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

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

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

2 $ - $ - $ - $ - $ - $ - $ -

I1 75

2

J1 80

2

K1 85

2

L1 90

2

M1 99

2

N1 00

2

SU

BS

YS

05 Cylinder Blocks

TECHNO

LOGY 

PACKAG

Item

Subsystem

Sub-Subsystem

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

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

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

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

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

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

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

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

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

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

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

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

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

#REF! #REF! #REF! #REF! #REF! #REF! #REF!

Material Labor Burden End Item 

Scrap SG&A Profit 

INCREMENTAL COST TO UPGRADE TO NEW 

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

NTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

A1 01 $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:10 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

B1 02

C1 03

D1 04

E1 65

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value Material Labor Burden End Item 

Scrap SG&A Profit 

BASE TECHNOLOGY GENERAL PAR

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

EW TECHNOLOGY GENERAL PART INFORMATION:

0 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

0kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

Small/Compact Vehicle Segment 

Passenger 2-5

(e.g. Ford Focus)

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

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

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

#REF! #REF! #REF! #REF! #REF! #REF! #REF!

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

F1 66

G1 67

H1 70

I1 75

J1 80

K1 85

L1 90

M1 99

N1 00

SU

BS

YS

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

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

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

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

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

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

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

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

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

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

#REF! #REF! #REF! #REF! #REF! #REF! #REF!

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:11 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

180600 Traction And High Voltage Power Distribution Subsystem

1 00

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

ED&T-R&D Material Labor Burden End Item 

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

$ - $ - $ - $ - $ - $ - $ - $ 1.41 $ 7.58 $ 2.63 $ 11.62 $ - $ - $ - $ - $ - $ - $ 11.62

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

2 01

3 02

4 03

5 75

6 80

7 80

8 85

9 99

$ - $ - $ - $ - $ - $ - $ - $ 121.81 $ 22.71 $ 11.56 $ 156.07 $ 0.78 $ 10.14 $ 9.36 $ 3.90 $ 24.19 $ 0.57 $ 180.84

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

$ - $ - $ - $ - $ - $ - $ - $ 0.30 $ 0.01 $ 0.11 $ 0.42 $ 0.00 $ 0.02 $ 0.02 $ 0.00 $ 0.05 $ 0.01 $ 0.47

$ - $ - $ - $ - $ - $ - $ - $ 1.34 $ 1.24 $ 1.47 $ 4.05 $ 0.01 $ 0.24 $ 0.16 $ 0.04 $ 0.46 $ 0.07 $ 4.58

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

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

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

$ - $ - $ - $ - $ - $ - $ - $ 2.15 $ 0.89 $ 0.39 $ 3.43 $ 0.02 $ 0.22 $ 0.21 $ 0.09 $ 0.53 $ 0.03 $ 3.99

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:12 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

ED&T-R&D Material Labor Burden End Item 

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

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

$ - $ - $ - $ - $ - $ - $ - $ 127.00 $ 32.43 $ 16.16 $ 175.58 $ 0.81 $ 10.64 $ 9.75 $ 4.03 $ 25.23 $ 0.68 $ 201.50

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:13 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

ED&T-R&D Material Labor Burden End Item 

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

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

05 Cylinder Blocks

A1 01

2

B1 02

2

C1 03

2

BASE 

TECHNO

LOGY 

Item

Subsystem

Sub-Subsystem

ED&T-R&D

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

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

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

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

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

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

System 

ED&T/R&D

(x1000)

BASE TECHNOLOGY PACKAGE COST INFORMATION

Tooling 

(x1000)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Investment

(X1000)

2

D1 04

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

#REF! #REF! #REF! #REF! $ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:14 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

2

E1 65

2

F1 66

2

G1 67

2

H1 70

2

ED&T-R&D Material Labor Burden End Item 

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

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

#REF! #REF! #REF! #REF! $ - $ - $ -

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

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

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

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

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

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

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

2 $ - $ - $ - $ - $ - $ - $ -

I1 75

2

J1 80

2

K1 85

2

L1 90

2

M1 99

2

N1 00

2

SU

BS

YS

05 Cylinder Blocks

TECHNO

LOGY 

PACKAG

Item

Subsystem

Sub-Subsystem

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

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

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

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

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

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

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

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

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

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

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

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

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

#REF! #REF! #REF! #REF! $ - $ - $ -

ED&T-R&D

MENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Investment

(X1000)

Tooling 

(x1000)

A1 01 $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:15 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

B1 02

C1 03

D1 04

E1 65

ED&T-R&D Material Labor Burden End Item 

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

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

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

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

#REF! #REF! #REF! #REF! $ - $ - $ -

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

F1 66

G1 67

H1 70

I1 75

J1 80

K1 85

L1 90

M1 99

N1 00

SU

BS

YS

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

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

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

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

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

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

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

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

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

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

#REF! #REF! #REF! #REF! $ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:1 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

Scrap SG&A Profit ED&T-R&D Material Labor Burden

180600 Traction And High Voltage Power Distribution Subsystem

1 00 Assembly of H Traction & HV Power Distribution Subsystem $ 1.41 $ 7.58 $ 2.63 $ 11.62 $ - $ - $ - $ - $ - $ - $ 11.62 $ - $ - $ - $ - $ - $ - $ -

2 01 HV Voltage Wire Harness & Connectors $ 121.81 $ 22.71 $ 11.56 $ 156.07 $ 0.78 $ 10.14 $ 9.36 $ 3.90 $ 24.19 $ 0.57 $ 180.84 $ - $ - $ - $ - $ - $ - $ -

3 02 HV External Protective Coverings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

4 03 HV Cable Grommet Assembly $ 0.30 $ 0.01 $ 0.11 $ 0.42 $ 0.00 $ 0.02 $ 0.02 $ 0.00 $ 0.05 $ 0.01 $ 0.47 $ - $ - $ - $ - $ - $ - $ -

5 75 Brackets $ 1.34 $ 1.24 $ 1.47 $ 4.05 $ 0.01 $ 0.24 $ 0.16 $ 0.04 $ 0.46 $ 0.07 $ 4.58 $ - $ - $ - $ - $ - $ - $ -

System 

ED&T/R&D

(x1000)

Investment

(X1000)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLO

2010 Ford Fusion, 3.0L 

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

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)

6 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

7 80 BIW Fasteners for HV Wire Harness Mounting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 99 Miscellaneous $ 2.15 $ 0.89 $ 0.39 $ 3.43 $ 0.02 $ 0.22 $ 0.21 $ 0.09 $ 0.53 $ 0.03 $ 3.99 $ - $ - $ - $ - $ - $ - $ -

SUBSYSTEM ROLL-UP $ 127.00 $ 32.43 $ 16.16 $ 175.58 $ 0.81 $ 10.64 $ 9.75 $ 4.03 $ 25.23 $ 0.68 $ 201.50 $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:2 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

Scrap SG&A Profit ED&T-R&D Material Labor Burden

System 

ED&T/R&D

(x1000)

Investment

(X1000)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLO

2010 Ford Fusion, 3.0L 

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

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)

BASE TECHNOLOGY PACKAGE COST INFORMATION

BASE 

TECHNO

LOGY 

BASE TECHNOLO

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:3 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

Scrap SG&A Profit ED&T-R&D Material Labor Burden

System 

ED&T/R&D

(x1000)

Investment

(X1000)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLO

2010 Ford Fusion, 3.0L 

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

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)

Material Labor Burden End Item 

Scrap SG&A Profit ED&T-R&D Material Labor Burden

05 Cylinder Blocks

A1 01 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B1 02 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Item

Subsystem

Sub-Subsystem

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Manufacturing Markup Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Total Markup 

Cost 

(Component/ 

Assembly)

Investment

(X1000)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

C1 03 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

D1 04 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - #REF! #REF! #REF! #REF!

2 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - #REF! #REF! #REF! #REF!

E1 65 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

F1 66 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

G1 67 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

H1 70 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

I1 75 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

J1 80 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

K1 85 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

L1 90 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

M1 99 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

N1 00 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SU

BS

YS

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - #REF! #REF! #REF! #REF!

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:4 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

Scrap SG&A Profit ED&T-R&D Material Labor Burden

System 

ED&T/R&D

(x1000)

Investment

(X1000)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLO

2010 Ford Fusion, 3.0L 

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

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)

Material Labor Burden End Item 

Scrap SG&A Profit ED&T-R&D Material Labor Burden

05 Cylinder Blocks

Item

Subsystem

Sub-Subsystem

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

TECHNO

LOGY 

PACKAG

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE INCREMENTAL COST TO U

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

A1 01 $ 1.41 $ 7.58 $ 2.63 $ 11.62 $ - $ - $ - $ - $ - $ - $ 11.62 $ - $ - $ - $ - $ - $ - $ -

B1 02 $ 121.81 $ 22.71 $ 11.56 $ 156.07 $ 0.78 $ 10.14 $ 9.36 $ 3.90 $ 24.19 $ 0.57 $ 180.84 $ - $ - $ - $ - $ - $ - $ -

C1 03 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

D1 04 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - #REF! #REF! #REF! #REF!

E1 65 $ 1.34 $ 1.24 $ 1.47 $ 4.05 $ 0.01 $ 0.24 $ 0.16 $ 0.04 $ 0.46 $ 0.07 $ 4.58 $ - $ - $ - $ - $ - $ - $ -

F1 66 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

G1 67 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

H1 70 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

I1 75 $ 2.15 $ 0.89 $ 0.39 $ 3.43 $ 0.02 $ 0.22 $ 0.21 $ 0.09 $ 0.53 $ 0.03 $ 3.99 $ - $ - $ - $ - $ - $ - $ -

J1 80 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

K1 85 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

L1 90 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

M1 99 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

N1 00 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:5 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

Scrap SG&A Profit ED&T-R&D Material Labor Burden

System 

ED&T/R&D

(x1000)

Investment

(X1000)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLO

2010 Ford Fusion, 3.0L 

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

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)

SU

BS

YS

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - #REF! #REF! #REF! #REF!

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:6 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

180600 Traction And High Voltage Power Distribution Subsystem

1 00

2 01

3 02

4 03

5 75

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

Scrap SG&A Profit ED&T-R&D Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 1.41 $ 7.58 $ 2.63 $ 11.62 $ - $ - $ - $ - $ - $ - $ 11.62 $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 121.81 $ 22.71 $ 11.56 $ 156.07 $ 0.78 $ 10.14 $ 9.36 $ 3.90 $ 24.19 $ 0.57 $ 180.84 $ - $ -

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 0.30 $ 0.01 $ 0.11 $ 0.42 $ 0.00 $ 0.02 $ 0.02 $ 0.00 $ 0.05 $ 0.01 $ 0.47 $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 1.34 $ 1.24 $ 1.47 $ 4.05 $ 0.01 $ 0.24 $ 0.16 $ 0.04 $ 0.46 $ 0.07 $ 4.58 $ - $ -

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

6 80

7 80

8 85

9 99

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

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

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 2.15 $ 0.89 $ 0.39 $ 3.43 $ 0.02 $ 0.22 $ 0.21 $ 0.09 $ 0.53 $ 0.03 $ 3.99 $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - ###### $ 32.43 $ 16.16 $ 175.58 $ 0.81 $ 10.64 $ 9.75 $ 4.03 $ 25.23 $ 0.68 $ 201.50 $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:7 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

Scrap SG&A Profit ED&T-R&D Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

BASE 

TECHNO

LOGY 

BASE TECHNOLOGY PACKAGE COST INFORMATION

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:8 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

05 Cylinder Blocks

A1 01

2

B1 02

Item

Subsystem

Sub-Subsystem

End Item 

Scrap SG&A Profit ED&T-R&D Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

End Item 

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

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

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

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

Investment

(X1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

2

C1 03

2

D1 04

2

E1 65

2

F1 66

2

G1 67

2

H1 70

2

I1 75

2

J1 80

2

K1 85

2

L1 90

2

M1 99

2

N1 00

2

SU

BS

YS

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

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

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

#REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ -

#REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ -

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

#REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:9 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

05 Cylinder Blocks

Item

Subsystem

Sub-Subsystem

TECHNO

LOGY 

PACKAG

End Item 

Scrap SG&A Profit ED&T-R&D Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

End Item 

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

Tooling 

(x1000)

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Investment

(X1000)

A1 01

B1 02

C1 03

D1 04

E1 65

F1 66

G1 67

H1 70

I1 75

J1 80

K1 85

L1 90

M1 99

N1 00

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

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

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

#REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ -

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

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

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

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

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

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

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

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

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

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

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

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:10 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

SU

BS

YS

End Item 

Scrap SG&A Profit ED&T-R&D Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

#REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:11 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

180600 Traction And High Voltage Power Distribution Subsystem

1 00

2 01

3 02

4 03

5 75

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

$ -

$ -

$ -

$ -

$ -

Investment(X1

000)

6 80

7 80

8 85

9 99

$ -

$ -

$ -

$ -

$ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:12 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

Investment(X1

000)

BASE 

TECHNO

LOGY 

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:13 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

05 Cylinder Blocks

A1 01 2

B1 02 Item Subsystem Sub-Subsystem

Investment(X1

000)

2

C1 03 2

D1 04 2

E1 65 2

F1 66 2

G1 67 2

H1 70 2

I1 75 2

J1 80 2

K1 85 2

L1 90 2

M1 99 2

N1 00 2

SU

BS

YS

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:14 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

05 Cylinder Blocks

Item

Subsystem

Sub-Subsystem

TECHNO

LOGY 

PACKAG

Investment(X1

000)

A1 01

B1 02

C1 03

D1 04

E1 65

F1 66

G1 67

H1 70

I1 75

J1 80

K1 85

L1 90

M1 99

N1 00

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:15 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

SU

BS

YS

Investment(X1

000)

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:1 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

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

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

180600 Traction And High Voltage Power Distribution Subsystem

1 00 Assembly of H Traction & HV Power Distribution Subsystem $ 1.41 $ 7.58 $ 2.63 $ 11.62 $ - $ - $ - $ - $ - $ - $ 11.62

A Installation of A Cabel Asm, High Voltage, to vehicle 18 06 00 - N0502- 01 1 Full 1

Includes VO assembly of harness to 

vehicle attachment points plus 

connector insertion labor @ Battery, 

e-CVT, DC-DC and AC 

Compressor.

$ 0.96 $ 7.58 $ 1.17 $ 9.71 $ - $ - $ - $ - $ - $ - $ 9.71

B Installation of BIW fasteners for attaching wire harness to vehicle 18 06 00 - N0502- 02 2 Full 1 $ 0.45 $ - $ 1.46 $ 1.91 $ - $ - $ - $ - $ - $ - $ 1.91

Sub-Subsystem

Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Item

Subsystem

NEW 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 HV Voltage Wire Harness & Connectors $ 121.81 $ 22.71 $ 11.56 $ 156.07 $ 0.78 $ 10.14 $ 9.36 $ 3.90 $ 24.19 $ 0.57 $ 180.84

A H Cable Asm, High Voltage (aka Wiring Harness - HEV underbody) 18 06 01 - N0502- 01 1 Full

A.1 H Cable Asm HV Covered -A- 18 06 01 - N0502- 01a 1 Full 1 $ 1.15 $ 2.60 $ 1.28 $ 5.03 $ 0.03 $ 0.33 $ 0.30 $ 0.13 $ 0.78 $ 0.57 $ 6.38

A.2 H HV Harn Asm w/ JB & Tape -B- 18 06 01 - N0502- 01b 1 Full 1 $ 2.06 $ 3.46 $ 1.87 $ 7.38 $ 0.04 $ 0.48 $ 0.44 $ 0.18 $ 1.14 $ - $ 8.53

A.3 H HV Harn Asm w/ Tape & Conn -C- 18 06 01 - N0502- 01c 1 Full 1 $ 1.27 $ 3.46 $ 1.72 $ 6.45 $ 0.03 $ 0.42 $ 0.39 $ 0.16 $ 1.00 $ - $ 7.45

A.4 H HV Harn Asm w/ Tape & Terminals -D- 18 06 01 - N0502- 01d 1 Full 1 $ 3.11 $ 6.56 $ 4.11 $ 13.78 $ 0.07 $ 0.90 $ 0.83 $ 0.34 $ 2.14 $ - $ 15.91

A.5 H HV Harn Misc Commodity Hardware Asm -E- 18 06 01 - N0502- 01e 1 Full 1 $ 3.81 $ 1.63 $ 0.63 $ 6.07 $ 0.03 $ 0.39 $ 0.36 $ 0.15 $ 0.94 $ - $ 7.01

A.6 H HV Harn Misc Commodity Hardware - AC #1 (28") -F- 18 06 01 - N0502- 01f 1 Full 1 $ 11.86 $ 1.20 $ 0.41 $ 13.47 $ 0.07 $ 0.88 $ 0.81 $ 0.34 $ 2.09 $ - $ 15.56

A.7 H HV Harn Misc Commodity Hardware - DC-DC #1 (51") -G- 18 06 01 - N0502- 01g 1 Full 1 $ 21.04 $ 1.05 $ 0.42 $ 22.51 $ 0.11 $ 1.46 $ 1.35 $ 0.56 $ 3.49 $ - $ 25.99

A.8 H HV Harn Misc Commodity Hardware - Trans (152") -H- 18 06 01 - N0502- 01h 1 Full 1 $ 55.05 $ 0.96 $ 0.39 $ 56.40 $ 0.28 $ 3.67 $ 3.38 $ 1.41 $ 8.74 $ - $ 65.14

A.9 H HV Harn Misc Commodity Hardware - BEC (154") -I- 18 06 01 - N0502- 01i 1 Full 1 $ 20.64 $ 1.07 $ 0.43 $ 22.14 $ 0.11 $ 1.44 $ 1.33 $ 0.55 $ 3.43 $ - $ 25.57

A.10 H HV Harn Misc Commodity Hardware - Comm FB -J- 18 06 01 - N0502- 01j 1 Full 1 $ 1.83 $ 0.72 $ 0.30 $ 2.85 $ 0.01 $ 0.18 $ 0.17 $ 0.07 $ 0.44 $ - $ 3.29

3 02 HV External Protective Coverings

4 03 HV Cable Grommet Assembly $ 0.30 $ 0.01 $ 0.11 $ 0.42 $ 0.00 $ 0.02 $ 0.02 $ 0.00 $ 0.05 $ 0.01 $ 0.47

A H Cover Cable Pass Thru 18 06 03 - N0502- 01 1 Full 1 $0.30 $0.01 $0.11 $0.42 $0.00 $0.02 $0.02 $0.00 $0.05 $0.01 $0.47

5 75 Brackets $ 1.34 $ 1.24 $ 1.47 $ 4.05 $ 0.01 $ 0.24 $ 0.16 $ 0.04 $ 0.46 $ 0.07 $ 4.58

A H Bracket Asm, HV Cable to Trans 18 06 75 - N0502- 01 1 Full 1 $ 0.89 $ 0.50 $ 0.70 $ 2.09 $ 0.01 $ 0.13 $ 0.08 $ 0.02 $ 0.24 $ 0.05 $ 2.37

B H Bracket Asm, HV Cable to Dash 18 06 75 - N0502- 02 1 Full 1 $ 0.45 $ 0.74 $ 0.77 $ 1.96 $ 0.01 $ 0.12 $ 0.08 $ 0.02 $ 0.22 $ 0.03 $ 2.20

6 80 Boltings Boltings $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ -

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: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

Sub-Subsystem

Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Item

Subsystem

NEW 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)

A H Bracket Asm, HV Cable to Trans 18 06 80 - N0502- 01 2 Full 1

PIA to installation of HV Harness 

Assembly $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B H Bracket Asm, HV Cable to Dash 18 06 80 - N0502- 02 3 Full 1

PIA to installation of HV Harness 

Assembly $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

C H Nut, HV Cable Mounts 18 06 80 - N0502- 03 10 Full 1

PIA to installation of HV Harness 

Assembly $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

D H Stud Harness to Trans Bracket 18 06 80 - N0502- 04 1 Full 1

PIA to installation of HV Harness 

Assembly $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

7 80 BIW Fasteners for HV Wire Harness Mounting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A H M6 Weld Stud, BIW 18 06 # - N0502- 01 7 Full 1

PIA to installation of BIW fasteners 

for attaching wire harness to vehicle $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B H M6 Weld Nut, BIW 18 06 # - N0502- 02 3 Full PIA to installation of BIW fasteners 

for attaching wire harness to vehicle $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

9 99 Miscellaneous $ 2.15 $ 0.89 $ 0.39 $ 3.43 $ 0.02 $ 0.22 $ 0.21 $ 0.09 $ 0.53 $ 0.03 $ 3.99

A H Battery Service Disconnect 18 06 99 - N0502- 01 1 Full 1 Service disconnect for HV battery $ 2.15 $ 0.89 $ 0.39 $ 3.43 $ 0.02 $ 0.22 $ 0.21 $ 0.09 $ 0.53 $ 0.03 $ 3.99

$ 127.00 $ 32.43 $ 16.16 $ 175.58 $ 0.81 $ 10.64 $ 9.75 $ 4.03 $ 25.23 $ 0.68 $ 201.50

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

Complete Subsystem Quote 

(Yes/No) Yes

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: 8/30/2012

DRAFT

0 n/a n/a

180600 Traction And High Voltage Power Distribution Subsystem

1 00 Assembly of H Traction & HV Power Distribution Subsystem

A Installation of A Cabel Asm, High Voltage, to vehicle 18 06 00 - N0502- 01 1 Full 1

Includes VO assembly of harness to 

vehicle attachment points plus 

connector insertion labor @ Battery, 

e-CVT, DC-DC and AC 

Compressor.

B Installation of BIW fasteners for attaching wire harness to vehicle 18 06 00 - N0502- 02 2 Full 1

Sub-Subsystem

Part Number

QTY/ Subsystem

Notes

Subassembly

Component

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Item

Subsystem

NEW 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)

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

System 

ED&T/R&D

(x1000)

Investment

(X1000)

Tooling 

(x1000)

2 01 HV Voltage Wire Harness & Connectors

A H Cable Asm, High Voltage (aka Wiring Harness - HEV underbody) 18 06 01 - N0502- 01 1 Full

A.1 H Cable Asm HV Covered -A- 18 06 01 - N0502- 01a 1 Full 1

A.2 H HV Harn Asm w/ JB & Tape -B- 18 06 01 - N0502- 01b 1 Full 1

A.3 H HV Harn Asm w/ Tape & Conn -C- 18 06 01 - N0502- 01c 1 Full 1

A.4 H HV Harn Asm w/ Tape & Terminals -D- 18 06 01 - N0502- 01d 1 Full 1

A.5 H HV Harn Misc Commodity Hardware Asm -E- 18 06 01 - N0502- 01e 1 Full 1

A.6 H HV Harn Misc Commodity Hardware - AC #1 (28") -F- 18 06 01 - N0502- 01f 1 Full 1

A.7 H HV Harn Misc Commodity Hardware - DC-DC #1 (51") -G- 18 06 01 - N0502- 01g 1 Full 1

A.8 H HV Harn Misc Commodity Hardware - Trans (152") -H- 18 06 01 - N0502- 01h 1 Full 1

A.9 H HV Harn Misc Commodity Hardware - BEC (154") -I- 18 06 01 - N0502- 01i 1 Full 1

A.10 H HV Harn Misc Commodity Hardware - Comm FB -J- 18 06 01 - N0502- 01j 1 Full 1

3 02 HV External Protective Coverings

4 03 HV Cable Grommet Assembly

A H Cover Cable Pass Thru 18 06 03 - N0502- 01 1 Full 1

5 75 Brackets

A H Bracket Asm, HV Cable to Trans 18 06 75 - N0502- 01 1 Full 1

B H Bracket Asm, HV Cable to Dash 18 06 75 - N0502- 02 1 Full 1

6 80 Boltings

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

6 80 Boltings $ $ - $ $ - $ $ -

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: 8/30/2012

DRAFT

Sub-Subsystem

Part Number

QTY/ Subsystem

Notes

Subassembly

Component

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Item

Subsystem

NEW 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)

A H Bracket Asm, HV Cable to Trans 18 06 80 - N0502- 01 2 Full 1

PIA to installation of HV Harness 

Assembly

B H Bracket Asm, HV Cable to Dash 18 06 80 - N0502- 02 3 Full 1

PIA to installation of HV Harness 

Assembly

C H Nut, HV Cable Mounts 18 06 80 - N0502- 03 10 Full 1

PIA to installation of HV Harness 

Assembly

D H Stud Harness to Trans Bracket 18 06 80 - N0502- 04 1 Full 1

PIA to installation of HV Harness 

Assembly

7 80 BIW Fasteners for HV Wire Harness Mounting

A H M6 Weld Stud, BIW 18 06 # - N0502- 01 7 Full 1

PIA to installation of BIW fasteners 

for attaching wire harness to vehicle

System 

ED&T/R&D

(x1000)

Investment

(X1000)

Tooling 

(x1000)

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

B H M6 Weld Nut, BIW 18 06 # - N0502- 02 3 Full PIA to installation of BIW fasteners 

for attaching wire harness to vehicle

8 85 Sealing Elements

9 99 Miscellaneous

A H Battery Service Disconnect 18 06 99 - N0502- 01 1 Full 1 Service disconnect for HV battery

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

Complete Subsystem Quote 

(Yes/No) Yes

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:1 of 2 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

180600 Traction And High Voltage Power Distribution Subsystem

1 00 Assembly of H Traction & HV Power Distribution Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

2 01 HV Voltage Wire Harness & Connectors $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

3 02 HV External Protective Coverings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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 HV Cable Grommet Assembly $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

5 75 Brackets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

6 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

7 80 BIW Fasteners for HV Wire Harness Mounting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

8 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

9 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 

the competing technology

Complete Subsystem Quote 

(Yes/No)

09000064810ec171.xls

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

Author: G. Kolwich

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

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

0

180600 Traction And High Voltage Power Distribution Subsystem

1 00 Assembly of H Traction & HV Power Distribution Subsystem

2 01 HV Voltage Wire Harness & Connectors

3 02 HV External Protective Coverings

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)

4 03 HV Cable Grommet Assembly

5 75 Brackets

6 80 Boltings

7 80 BIW Fasteners for HV Wire Harness Mounting

8 85 Sealing Elements

9 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 

the competing technology

Complete Subsystem Quote 

(Yes/No)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: OEM Vehicle Assembly

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: Installation of BIW fasteners for attaching wire harness to vehicle Part Number: 180600-N0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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 1A Body Shop Assembly of Weld Nuts and Studs 

for Wire Harness 180600-N0502-02 7 BIW Weld Assembly OEM Vehicle Assembly Not Applicable General Assembly-OEM VO Assembly, OEM, MHC 3240 0 9 1 0.000 $0.00 $97.48 $75.00 $675.00 $0.00 $0.00 $0.21 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $1.46 $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

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

Power-Split HEV Technology

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

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

22 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

23 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

24 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

25 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

26 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

27 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 3 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 2 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 1.1 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

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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: OEM Vehicle Assembly

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: Installation of BIW fasteners for attaching wire harness to vehicle Part Number: 180600-N0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

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

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

22 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

23 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

24 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

25 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

26 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

27 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 A H M6 Weld Stud, BIW 180681-N0502-01 7 S $0.00 $0.05 $0.00 $0.35 $0.35

3 B H M6 Weld Nut, BIW 180681-N0502-01 2 S $0.00 $0.05 $0.00 $0.10 $0.10

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

"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: 3 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: OEM Vehicle Assembly

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: Installation of BIW fasteners for attaching wire harness to vehicle Part Number: 180600-N0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

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 $0.000 $0.00 $0.00 $0.00

8 0 $0.00 $0.000 $0.00 $0.00 $0.00

9 0 $0.00 $0.000 $0.00 $0.00 $0.00

10 0 $0.00 $0.000 $0.00 $0.00 $0.00

11 0 $0.00 $0.000 $0.00 $0.00 $0.00

12 0 $0.00 $0.000 $0.00 $0.00 $0.00

13 0 $0.00 $0.000 $0.00 $0.00 $0.00

14 0 $0.00 $0.000 $0.00 $0.00 $0.00

15 0 $0.00 $0.000 $0.00 $0.00 $0.00

Mark-up Calculations.

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

Supplier for Subassembly.

16 0 $0.00 $0.000 $0.00 $0.00 $0.00

17 0 $0.00 $0.000 $0.00 $0.00 $0.00

21 0 $0.00 $0.000 $0.00 $0.00 $0.00

22 0 $0.00 $0.000 $0.00 $0.00 $0.00

23 0 $0.00 $0.000 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.45

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

Mark-up $1.91

T1 or OEM Total Manufacturing Cost: $0.45 $0.00 $1.46 $1.91 $0.00 $0.00 $0.00 $0.00 $0.00 $1.91

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.00 $0.00 $0.00 $0.00

Base Cost Impact to Vehicle: $0.45 $0.00 $1.46 $1.91 $0.00 $0.00 $0.00 $0.00 $0.00 $1.91 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $1.91

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:

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable Last 5 Years

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/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

Number of Layers: 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.)

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: OEM Vehicle Assembly

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: Installation of BIW fasteners for attaching wire harness to vehicle Part Number: 180600-N0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

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: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

1A Body Shop Assembly of Weld Nuts and Studs 

for Wire Harness 180600-N0502-02

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

R/D = Rundown 

$0.00 $1.46 $1.46 $0.00 $0.00 $0.00 $0.00 $0.00

Projection Weld Nuts and Studs onto BIW for harness attachment, 4 locations in 

total. Assumption - weld nuts added to component panels and studs are 

assembled to BIW vehicle. Stations are completely automated.

Estmate average cycle time of 10 seconds/fastener.

5 2 10 100 47 4700 670 5.37 85% 788 4.57 - 1 1 10 1.0 9.0

$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)

$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

$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 3.0

$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 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! #DIV/0! 85% 0 #DIV/0! #DIV/0! - - - - 1.1 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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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

$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

$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)

A H M6 Weld Stud, BIW 180681-N0502-01

B H M6 Weld Nut, BIW 180681-N0502-01

$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

$0.35

$0.10

$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: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$0.00 $1.46 $1.91 $0.00 $0.00 $0.00 $0.00 $0.00

$1.91

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: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

1A Body Shop Assembly of Weld Nuts and Studs 

for Wire Harness 180600-N0502-02

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

3240 1.11 -

#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)

#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! -

#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! -

#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: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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

#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! -

#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)

A H M6 Weld Stud, BIW 180681-N0502-01

B H M6 Weld Nut, BIW 180681-N0502-01

#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: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: OEM Vehicle Assembly

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 Traction & HV Power Distribution Subsystem Assembly Part Number: 180600-N0502-01 Weekly Component Volume: Packaging Specification: n/a

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

H Traction & HV Power Harness - Bracket, 

Trans Axle 180600-N0502-01-01 1 Bolt (2x) bracket to vehicle OEM Vehicle Assembly Not Applicable General Assembly-OEM VO Assembly, OEM, LC 180 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.54 $0.08 $0.62 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.62 $0.62 $0.00

2 H Traction & HV Power Harness - Bracket, Dash 180600-N0502-01-02 1 Bolt (3x) bracket to vehicle OEM Vehicle Assembly Not Applicable General Assembly-OEM VO Assembly, OEM, LC 129 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.76 $0.12 $0.87 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.87 $0.87 $0.00

3 H Traction & HV Power Harness - Bracket, Dash 180600-N0502-01-03 1

Attach harn to dash bracket, 

press xmas clips (2x), torque h 

nuts (2x) w/ tool

OEM Vehicle Assembly Not Applicable General Assembly-OEM VO Assembly, OEM, LC 189 2 1 2 0.000 $0.00 $97.48 $15.00 $30.00 $0.00 $1.03 $0.16 $1.19 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.19 $1.19 $0.00

4

H Traction & HV Power Harness - Route harn 

asm

180600-N0502-01-04 1

Attach harn asm & route along 

vehicle floor, install & torque h OEM Vehicle Assembly Not Applicable General Assembly-OEM VO Assembly, OEM, LC 138 2 1 2 0.000 $0.00 $97.48 $15.00 $30.00 $0.00 $1.41 $0.22 $1.62 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.62 $1.62 $0.00

Costs Broken Out In

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

Power-Split HEV Technology

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)

4

asm

180600-N0502-01-04 1 vehicle floor, install & torque h 

nuts (5x) w/ tool

OEM Vehicle Assembly Not Applicable General Assembly-OEM VO Assembly, OEM, LC 138 2 1 2 0.000 $0.00 $97.48 $15.00 $30.00 $0.00 $1.41 $0.22 $1.62 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.62 $1.62 $0.00

5

H Traction & HV Power Harness - Route & floor 

mount 180600-N0502-01-05 1

Route harn along floor, attach 

mount to floor pass-thru & 

press xmas clips (2x)

OEM Vehicle Assembly Not Applicable General Assembly-OEM VO Assembly, OEM, LC 129 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.76 $0.12 $0.87 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.87 $0.87 $0.00

6

H Traction & HV Power Harness - Route & floor 

mount 180600-N0502-01-06 1

Press xmas clips (2x), install h 

nuts (3x) & torque OEM Vehicle Assembly Not Applicable General Assembly-OEM VO Assembly, OEM, LC 180 2 1 2 0.000 $0.00 $97.48 $15.00 $30.00 $0.00 $1.08 $0.17 $1.25 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.25 $1.25 $0.00

7

H Traction & HV Power Harness - Cover Cable 

Pass-Thru & Transaxle Power Cable 180600-N0502-01-07 1

Install cover & snap, engange 

transaxle controller power push 

in conn & lock cam, install stud 

harn to trans bracket & torque

OEM Vehicle Assembly Not Applicable General Assembly-OEM VO Assembly, OEM, LC 113 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.87 $0.13 $1.00 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.00 $1.00 $0.00

8

H Traction & HV Power Harness - AC 

Compressor Power Cable 180600-N0502-01-08 1

Enange AC compressor power, 

route calbe & push in connector OEM Vehicle Assembly Not Applicable General Assembly-OEM VO Assembly, OEM, LC 257 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.38 $0.06 $0.44 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.44 $0.44 $0.00

9

H Traction & HV Power Harness - HV Cables 

Dist Box & Battery 180600-N0502-01-09 1

Route HV cables to battery, 

press clip, push in conn & lock 

cam, engage batt srv disconn, 

push in conn & lock cam

OEM Vehicle Assembly Not Applicable General Assembly-OEM VO Assembly, OEM, LC 129 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.76 $0.12 $0.87 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.87 $0.87 $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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: OEM Vehicle Assembly

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 Traction & HV Power Distribution Subsystem Assembly Part Number: 180600-N0502-01 Weekly Component Volume: Packaging Specification: n/a

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

30 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

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

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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

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

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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: OEM Vehicle Assembly

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 Traction & HV Power Distribution Subsystem Assembly Part Number: 180600-N0502-01 Weekly Component Volume: Packaging Specification: n/a

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 H Bolt - Bracket, Trans 180600-N0502-01-11 2 S $0.00 $0.15 $0.00 $0.30 $0.30

2 H Bolt - Bracket, Dash 180600-N0502-01-12 3 S $0.00 $0.06 $0.00 $0.18 $0.18

3 H Nut - Dash 180600-N0502-01-13 2 S $0.00 $0.04 $0.00 $0.08 $0.08

4 H Nut - Floor 180600-N0502-01-14 5 S $0.00 $0.04 $0.00 $0.20 $0.20

5 H Nut - Floor 180600-N0502-01-15 3 S $0.00 $0.04 $0.00 $0.12 $0.12

6 H Stud 180600-N0502-01-16 1 S $0.00 $0.08 $0.00 $0.08 $0.08

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 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 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.

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

Supplier for Subassembly.

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.96

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: OEM Vehicle Assembly

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 Traction & HV Power Distribution Subsystem Assembly Part Number: 180600-N0502-01 Weekly Component Volume: Packaging Specification: n/a

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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

Mark-up $9.71

T1 or OEM Total Manufacturing Cost: $0.96 $7.58 $1.17 $9.71 $0.00 $0.00 $0.00 $0.00 $0.00 $9.71

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.00 $0.00 $0.00 $0.00

Base Cost Impact to Vehicle: $0.96 $7.58 $1.17 $9.71 $0.00 $0.00 $0.00 $0.00 $0.00 $9.71 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $9.71

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 Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable 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: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H Traction & HV Power Harness - Bracket, 

Trans Axle 180600-N0502-01-01

H Traction & HV Power Harness - Bracket, Dash 180600-N0502-01-02

H Traction & HV Power Harness - Bracket, Dash 180600-N0502-01-03

H Traction & HV Power Harness - Route harn 

asm

180600-N0502-01-04

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

$0.54 $0.08 $0.62 $0.00 $0.00 $0.00 $0.00 $0.00 Operator mount bracket (Trans Axle) to vehicle with bolts (2x) utilizing power torque tool 5 2 10 100 47 4700 96 37.60 85% 113 31.96 23 1 1 20 1.0 1.0

$0.76 $0.12 $0.87 $0.00 $0.00 $0.00 $0.00 $0.00 Operator mount bracket (Dash) to vehicle with bolts (3x) utilizing power torque tool 5 2 10 100 47 4700 96 37.60 85% 113 31.96 43 1 1 28 1.0 1.0

$1.03 $0.16 $1.19 $0.00 $0.00 $0.00 $0.00 $0.00 Operator asm harn to dash bracket, press xmas clips (3x) & attach nuts (2x) w/ power tool assist 5 2 10 100 47 4700 96 37.60 85% 113 31.96 46 1 1 19 2.0 1.0

$1.41 $0.22 $1.62 $0.00 $0.00 $0.00 $0.00 $0.00 Operator route harn asm along vehicle floor, secure by installing & torque nuts (5x) w/ power assist tool 5 2 10 100 47 4700 96 37.60 85% 113 31.96 72 1 1 26 2.0 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

asm

180600-N0502-01-04

H Traction & HV Power Harness - Route & floor 

mount 180600-N0502-01-05

H Traction & HV Power Harness - Route & floor 

mount 180600-N0502-01-06

H Traction & HV Power Harness - Cover Cable 

Pass-Thru & Transaxle Power Cable 180600-N0502-01-07

H Traction & HV Power Harness - AC 

Compressor Power Cable 180600-N0502-01-08

H Traction & HV Power Harness - HV Cables 

Dist Box & Battery 180600-N0502-01-09

$1.41 $0.22 $1.62 $0.00 $0.00 $0.00 $0.00 $0.00 Operator route harn asm along vehicle floor, secure by installing & torque nuts (5x) w/ power assist tool 5 2 10 100 47 4700 96 37.60 85% 113 31.96 72 1 1 26 2.0 1.0

$0.76 $0.12 $0.87 $0.00 $0.00 $0.00 $0.00 $0.00 Operator route harn asm along vehicle floor, install floor mount frame to pass-thru hole & press xmas clips 5 2 10 100 47 4700 96 37.60 85% 113 31.96 34 1 1 28 1.0 1.0

$1.08 $0.17 $1.25 $0.00 $0.00 $0.00 $0.00 $0.00 Operator route harn asm, press xmas clips (2x), install h nuts (3x) & torque w/ power assist tool 5 2 10 100 47 4700 96 37.60 85% 113 31.96 45 1 1 20 2.0 1.0

$0.87 $0.13 $1.00 $0.00 $0.00 $0.00 $0.00 $0.00 Operator install cover cable pass-thru & snap together, engange transaxle controller power push in 

connector & lock cam, install stud harn to trans bracket & torque 5 2 10 100 47 4700 96 37.60 85% 113 31.96 40 1 1 32 1.0 1.0

$0.38 $0.06 $0.44 $0.00 $0.00 $0.00 $0.00 $0.00 Operator engange AC compressor power push in connector 5 2 10 100 47 4700 96 37.60 85% 113 31.96 14 1 1 14 1.0 1.0

$0.76 $0.12 $0.87 $0.00 $0.00 $0.00 $0.00 $0.00 Operator route HV cables to battery, press clip, push in conn & lock cam, engage batt srv disconn, push in 

conn & lock cam 5 2 10 100 47 4700 96 37.60 85% 113 31.96 31 1 1 28 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

$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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

Purchase Part - High Impact Item (Full Cost Mapping)

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

$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

$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! #DIV/0! 85% 0 #DIV/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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 $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)

H Bolt - Bracket, Trans 180600-N0502-01-11

H Bolt - Bracket, Dash 180600-N0502-01-12

H Nut - Dash 180600-N0502-01-13

H Nut - Floor 180600-N0502-01-14

H Nut - Floor 180600-N0502-01-15

H Stud 180600-N0502-01-16

$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

$0.30

$0.18

$0.08

$0.20

$0.12

$0.08

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$7.58 $1.17 $9.71 $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: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

$9.71

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: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H Traction & HV Power Harness - Bracket, 

Trans Axle 180600-N0502-01-01

H Traction & HV Power Harness - Bracket, Dash 180600-N0502-01-02

H Traction & HV Power Harness - Bracket, Dash 180600-N0502-01-03

H Traction & HV Power Harness - Route harn 

asm

180600-N0502-01-04

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

180 20.00 1.00

129 28.00 1.00

189 19.00 2.00

138 26.00 2.00

asm

180600-N0502-01-04

H Traction & HV Power Harness - Route & floor 

mount 180600-N0502-01-05

H Traction & HV Power Harness - Route & floor 

mount 180600-N0502-01-06

H Traction & HV Power Harness - Cover Cable 

Pass-Thru & Transaxle Power Cable 180600-N0502-01-07

H Traction & HV Power Harness - AC 

Compressor Power Cable 180600-N0502-01-08

H Traction & HV Power Harness - HV Cables 

Dist Box & Battery 180600-N0502-01-09

138 26.00 2.00

129 28.00 1.00

180 20.00 2.00

113 32.00 1.00

257 14.00 1.00

129 28.00 1.00

#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! -

#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: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

Purchase Part - High Impact Item (Full Cost Mapping)

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

#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! -

#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! -

#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: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

#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)

H Bolt - Bracket, Trans 180600-N0502-01-11

H Bolt - Bracket, Dash 180600-N0502-01-12

H Nut - Dash 180600-N0502-01-13

H Nut - Floor 180600-N0502-01-14

H Nut - Floor 180600-N0502-01-15

H Stud 180600-N0502-01-16

#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: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Cable Asm HV Covered Part Number: 180601-N0502-01a Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

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

Power-Split HEV Technology

MARK-UP COSTS Manufacturing C

Costs Broken O

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 H Cable Asm HV Covered 020201-N0502-01a-01 1

Unpack and orient HV harn to 

BEC end

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 200 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.19 $0.08 $0.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $0.27 $0.00

2 H Cable Asm HV Covered - Cover #3 020201-N0502-01a-02 1

Assemble cover #3 over wires 

(4x)-BEC end harn

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 171 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.22 $0.09 $0.31 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.31 $0.31 $0.00

3 H Cable Asm HV Covered - Cover #3 020201-N0502-01a-03 1

Tape cover #3 closed, orient & T1 Assembly, Mark-up Applied 3 H Cable Asm HV Covered - Cover #3 020201-N0502-01a-03 1 Not Applicable General Assembly Mech Assembly, LC, Base 180 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.21 $0.08 $0.30 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.30 $0.30 $0.00 Tape cover #3 closed, orient & 

reposition

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 180 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.21 $0.08 $0.30 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.30 $0.30 $0.00

4 H Cable Asm HV Covered - Lwr Cover #1 020201-N0502-01a-04 1 Place wires (4x) into cover slots T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 225 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.17 $0.07 $0.24 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.24 $0.24 $0.00

5

H Cable Asm HV Covered - DC-AC Console 

Harness 020201-N0502-01a-05 1

Assemble DC-AC harn asm in 

lwr cover #1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 277 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.14 $0.05 $0.19 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.19 $0.19 $0.00

6 H Cable Asm HV Covered - Upper Cover #1 020201-N0502-01a-06 1

Assemble upr cover #1 onto 

Lwr cover #1 & snap close & 

apply tape

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 171 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.22 $0.09 $0.31 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.31 $0.31 $0.00

7 H Cable Asm HV Covered - Upper Cover #1 020201-N0502-01a-07 1

Apply duct tape to secure cover 

halves & reposition

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 138 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.28 $0.11 $0.39 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.39 $0.39 $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: 2 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Cable Asm HV Covered Part Number: 180601-N0502-01a Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

MARK-UP COSTS Manufacturing C

Costs Broken O

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 H Cable Asm HV Covered - Lwr Cover #2 020201-N0502-01a-08 1 Place wires (5x) into cover slots T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 225 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.17 $0.07 $0.24 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.24 $0.24 $0.00

9 H Cable Asm HV Covered - Upper Cover #2 020201-N0502-01a-09 1

Assemble upr cover #2 onto 

Lwr cover #2 & snap close & 

apply tape

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 150 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.26 $0.10 $0.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.36 $0.36 $0.00

10 H Cable Asm HV Covered - Tear Tape 020201-N0502-01a-10 1

Apply tear tape to secure harn 

asm at 3 locations for shipping

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 157 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.49 $0.19 $0.68 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.68 $0.68 $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 H HV Harness Lower Cover #1 - Push Pins 020201-N0502-01a-11 1

Assemble push pins (2x) to 

lower cover #1

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 189 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.20 $0.08 $0.28 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.28 $0.28 $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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 H HV Harness Cover #3 020201-N0502-01a-12 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, LS 1800 0.25 1 1 0.164 $1.74 $41.48 $151.77 $151.77 $0.29 $0.01 $0.08 $0.38 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.38 $0.38 $0.29

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 H HV Harness Lower Cover #1 020201-N0502-01a-13 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, LS 1800 0.25 1 1 0.164 $1.74 $41.48 $151.77 $151.77 $0.29 $0.01 $0.08 $0.38 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.38 $0.38 $0.29

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 H HV Harness Upper Cover #1 020201-N0502-01a-14 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, LS 1800 0.25 1 1 0.138 $1.74 $41.48 $151.77 $151.77 $0.24 $0.01 $0.08 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.24

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 H HV Harness Lower Cover #2 020201-N0502-01a-15 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 1543 0.25 1 1 0.057 $1.74 $41.48 $28.80 $28.80 $0.10 $0.01 $0.02 $0.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.12 $0.12 $0.10

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 H HV Harness Upper Cover #2 020201-N0502-01a-16 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 2400 0.25 1 1 0.024 $1.74 $41.48 $28.80 $28.80 $0.04 $0.00 $0.01 $0.06 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.06 $0.06 $0.04

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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Cable Asm HV Covered Part Number: 180601-N0502-01a Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

MARK-UP COSTS Manufacturing C

Costs Broken O

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 Black Duct Tape - 3/4"W 020201-N0502-01a-17 0.854 S $0.00 $0.01 $0.00 $0.01 $0.01

2 0 $0.00 $0.00 $0.00 $0.00 $0.00

3 Push Pin - approx 3/8" Dia 020201-N0502-01a-18 2 S $0.00 $0.03 $0.00 $0.06 $0.06

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

1 Black Duct Tape - 3/4"W 020201-N0502-01a-19 1.25 S $0.00 $0.01 $0.00 $0.01 $0.01

1 Black Duct Tape - 3/4"W 020201-N0502-01a-20 4.417 S $0.00 $0.01 $0.00 $0.05 $0.05

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

1 Black Duct Tape - 3/4"W 020201-N0502-01a-21 0.792 S $0.00 $0.01 $0.00 $0.01 $0.01

1 Black Duct Tape - 3/4"W 020201-N0502-01a-22 1.25 S $0.00 $0.01 $0.00 $0.01 $0.01

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

1 Black Tear Tape - 3/8"W 020201-N0502-01a-23 0.917 S $0.00 $0.01 $0.00 $0.01 $0.01

1 Black Tear Tape - 3/8"W 020201-N0502-01a-24 0.729 S $0.00 $0.01 $0.00 $0.01 $0.01

1 Black Tear Tape - 3/8"W 020201-N0502-01a-25 1.542 S $0.00 $0.01 $0.00 $0.02 $0.02

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 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.

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

Supplier for Subassembly.

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$1.15

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Cable Asm HV Covered Part Number: 180601-N0502-01a Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

MARK-UP COSTS Manufacturing C

Costs Broken O

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 $5.03

T1 or OEM Total Manufacturing Cost: $1.15 $2.60 $1.28 $5.03 $0.00 $0.00 $0.00 $0.00 $0.00 $5.03

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 $0.30 $0.13 $0.78

Base Cost Impact to Vehicle: $1.15 $2.60 $1.28 $5.03 $0.03 $0.33 $0.30 $0.13 $0.78 $5.81 $0 $0

Packaging Cost: $0.57

Net Cost Impact to Vehicle: $6.38

3

1

Notes: 

a) Items 1,2, & 3 m

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: $0.575 $1,149,000 0.00% 2,250,000 60 5.00% $300 3830 15 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: $0.575

PACKAGING CALCULATIONS: 

Packaging Type: Option #1

Part Size: 26" x 26" x 6"

Parts/Layer: 3

Number of Layers: 5

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable 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: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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)

H Cable Asm HV Covered 020201-N0502-01a-01

H Cable Asm HV Covered - Cover #3 020201-N0502-01a-02

H Cable Asm HV Covered - Cover #3 020201-N0502-01a-03

$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

$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

$0.19 $0.08 $0.27 $0.00 $0.00 $0.00 $0.00 $0.00 Operator unpack HV harn asm from dunnage and orient and position to BEC end 5 2 10 100 47 4700 96 37.60 85% 113 31.96 18 1 1 18 1.0 1.0

$0.22 $0.09 $0.31 $0.00 $0.00 $0.00 $0.00 $0.00 Operator place bracket over harn wires (4x) and snap together halves (2 positions) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 25 1 1 21 1.0 1.0

H Cable Asm HV Covered - Cover #3 020201-N0502-01a-03 $0.21 $0.08 $0.30 $0.00 $0.00 $0.00 $0.00 $0.00 Operator installs black duct tape to secure cover halves together, reposition harn asm 5 2 10 100 47 4700 96 37.60 85% 113 31.96 21 1 1 20 1.0 1.0

H Cable Asm HV Covered - Lwr Cover #1 020201-N0502-01a-04

H Cable Asm HV Covered - DC-AC Console 

Harness 020201-N0502-01a-05

H Cable Asm HV Covered - Upper Cover #1 020201-N0502-01a-06

H Cable Asm HV Covered - Upper Cover #1 020201-N0502-01a-07

$0.21 $0.08 $0.30 $0.00 $0.00 $0.00 $0.00 $0.00 Operator installs black duct tape to secure cover halves together, reposition harn asm 5 2 10 100 47 4700 96 37.60 85% 113 31.96 21 1 1 20 1.0 1.0

$0.17 $0.07 $0.24 $0.00 $0.00 $0.00 $0.00 $0.00 Operator place wires (4x) into lower cover 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 1 1 16 1.0 1.0

$0.14 $0.05 $0.19 $0.00 $0.00 $0.00 $0.00 $0.00 Operator place DC-AC harn into lower cover #1 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0

$0.22 $0.09 $0.31 $0.00 $0.00 $0.00 $0.00 $0.00 Operator place upper cover #1 over lower cover, snap together halves (6 positions), snap cover asm to 

harness clip, apply duct tape (15") 5 2 10 100 47 4700 96 37.60 85% 113 31.96 25 1 1 21 1.0 1.0

$0.28 $0.11 $0.39 $0.00 $0.00 $0.00 $0.00 $0.00 Operator apply duct tape (53") to secure cover halves & reposition harn asm for next assembly step 5 2 10 100 47 4700 96 37.60 85% 113 31.96 30 1 1 26 1.0 1.0

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

H Cable Asm HV Covered - Lwr Cover #2 020201-N0502-01a-08

H Cable Asm HV Covered - Upper Cover #2 020201-N0502-01a-09

H Cable Asm HV Covered - Tear Tape 020201-N0502-01a-10

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

$0.17 $0.07 $0.24 $0.00 $0.00 $0.00 $0.00 $0.00 Operator place wires (5x) into lower cover #2 5 2 10 100 47 4700 96 37.60 85% 113 31.96 18 1 1 16 1.0 1.0

$0.26 $0.10 $0.36 $0.00 $0.00 $0.00 $0.00 $0.00 Operator place upper cover #2 over lower cover, snap together halves (2 positions), apply duct tape (9.5" 

& 15") 5 2 10 100 47 4700 96 37.60 85% 113 31.96 26 1 1 24 1.0 1.0

$0.49 $0.19 $0.68 $0.00 $0.00 $0.00 $0.00 $0.00 Operator apply tear tape (3 locations) to secure harn asm for shipping 5 2 10 100 47 4700 96 37.60 85% 113 31.96 52 1 1 46 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

H HV Harness Lower Cover #1 - Push Pins 020201-N0502-01a-11

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

H HV Harness Cover #3 020201-N0502-01a-12

H HV Harness Lower Cover #1 020201-N0502-01a-13

H HV Harness Upper Cover #1 020201-N0502-01a-14

$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

$0.20 $0.08 $0.28 $0.00 $0.00 $0.00 $0.00 $0.00 Operator place cover in fixture and load push pins to press head, cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 19 1 1 19 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

$0.01 $0.08 $0.38 $0.00 $0.00 $0.00 $0.00 $0.00 400-800 Ton Injection Molding w/ 6 cavity mold for Harness Cover #3, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 12 1 6 12 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

$0.01 $0.08 $0.38 $0.00 $0.00 $0.00 $0.00 $0.00 400-800 Ton Injection Molding w/ 6 cavity mold for Harness Lower Cover #1, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 12 1 6 12 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

$0.01 $0.08 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 400-800 Ton Injection Molding w/ 6 cavity mold for Harness Upper Cover #1, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 12 1 6 12 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

H HV Harness Lower Cover #2 020201-N0502-01a-15

H HV Harness Upper Cover #2 020201-N0502-01a-16

$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

$0.01 $0.02 $0.12 $0.00 $0.00 $0.00 $0.00 $0.00 200-400 Ton Injection Molding w/ 10 cavity mold for Harness Lower Cover #2, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 14 1 6 14 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 $0.01 $0.06 $0.00 $0.00 $0.00 $0.00 $0.00 200-400 Ton Injection Molding w/ 10 cavity mold for Harness Upper Cover #2, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 9 1 6 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

$0.00 $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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

$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)

Black Duct Tape - 3/4"W 020201-N0502-01a-17

Push Pin - approx 3/8" Dia 020201-N0502-01a-18

Black Duct Tape - 3/4"W 020201-N0502-01a-19

Black Duct Tape - 3/4"W 020201-N0502-01a-20

Black Duct Tape - 3/4"W 020201-N0502-01a-21

Black Duct Tape - 3/4"W 020201-N0502-01a-22

Black Tear Tape - 3/8"W 020201-N0502-01a-23

Black Tear Tape - 3/8"W 020201-N0502-01a-24

Black Tear Tape - 3/8"W 020201-N0502-01a-25

$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

$0.01

$0.00

$0.06

$0.00

$0.01

$0.05

$0.00

$0.01

$0.01

$0.00

$0.01

$0.01

$0.02

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$2.60 $1.28 $5.03 $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: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

$5.03

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: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H Cable Asm HV Covered 020201-N0502-01a-01

H Cable Asm HV Covered - Cover #3 020201-N0502-01a-02

H Cable Asm HV Covered - Cover #3 020201-N0502-01a-03

#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! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

200 18.00 1.00

171 21.00 1.00

H Cable Asm HV Covered - Cover #3 020201-N0502-01a-03 180 20.00 1.00

H Cable Asm HV Covered - Lwr Cover #1 020201-N0502-01a-04

H Cable Asm HV Covered - DC-AC Console 

Harness 020201-N0502-01a-05

H Cable Asm HV Covered - Upper Cover #1 020201-N0502-01a-06

H Cable Asm HV Covered - Upper Cover #1 020201-N0502-01a-07

180 20.00 1.00

225 16.00 1.00

277 13.00 1.00

171 21.00 1.00

138 26.00 1.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

H Cable Asm HV Covered - Lwr Cover #2 020201-N0502-01a-08

H Cable Asm HV Covered - Upper Cover #2 020201-N0502-01a-09

H Cable Asm HV Covered - Tear Tape 020201-N0502-01a-10

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

225 16.00 1.00

150 24.00 1.00

157 23.00 2.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

H HV Harness Lower Cover #1 - Push Pins 020201-N0502-01a-11

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

H HV Harness Cover #3 020201-N0502-01a-12

H HV Harness Lower Cover #1 020201-N0502-01a-13

H HV Harness Upper Cover #1 020201-N0502-01a-14

#DIV/0! #DIV/0! -

189 19.00 1.00

#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! -

1800 2.00 0.25

#DIV/0! #DIV/0! -

1800 2.00 0.25

#DIV/0! #DIV/0! -

1800 2.00 0.25

#DIV/0! #DIV/0! -

H HV Harness Lower Cover #2 020201-N0502-01a-15

H HV Harness Upper Cover #2 020201-N0502-01a-16

#DIV/0! #DIV/0! -

1543 2.33 0.25

#DIV/0! #DIV/0! -

2400 1.50 0.25

#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: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

#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)

Black Duct Tape - 3/4"W 020201-N0502-01a-17

Push Pin - approx 3/8" Dia 020201-N0502-01a-18

Black Duct Tape - 3/4"W 020201-N0502-01a-19

Black Duct Tape - 3/4"W 020201-N0502-01a-20

Black Duct Tape - 3/4"W 020201-N0502-01a-21

Black Duct Tape - 3/4"W 020201-N0502-01a-22

Black Tear Tape - 3/8"W 020201-N0502-01a-23

Black Tear Tape - 3/8"W 020201-N0502-01a-24

Black Tear Tape - 3/8"W 020201-N0502-01a-25

#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: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Asm w/ JB & Tape Part Number: 180601-N0502-01b Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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

H HV Harn Asm w/ JB & Tape - H Bracket Clip 

Asm 180601-N0502-01b-01 1

Unpack HV harn & orient for 

assembly & Install H Bracket 

Clip

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 164 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.24 $0.09 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

2

H HV Harn Asm w/ JB & Tape - Black Duct 

Tape 180601-N0502-01b-02 1 Install tape on bracket asm T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 180 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.21 $0.08 $0.30 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.30 $0.30 $0.00

3

H HV Harn Asm w/ JB & Tape - Harn Lwr Cvr 

#4 180601-N0502-01b-03 1

Install lwr cover, place 3 wires, 

tape & place 3 wires

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 120 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.32 $0.13 $0.45 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.45 $0.45 $0.00

4

H HV Harn Asm w/ JB & Tape - Harn Upr Cvr 

#4 180601-N0502-01b-04 1

Orient & install upr cover & 

Reposition

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 164 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.24 $0.09 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

5

H HV Harn Asm w/ JB & Tape - Lower Cover 

Asm #5 180601-N0502-01b-05 1

Insert cables, wrap tie to cover 

(2x) & trim to length

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 171 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.45 $0.18 $0.62 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.62 $0.62 $0.00

6

H HV Harn Asm w/ JB & Tape - Lower Cover 

Asm #5 180601-N0502-01b-06 1

Assemble upr to lwr cover, 

snap together, apply tape, 

reposition

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 225 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.34 $0.13 $0.48 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.48 $0.48 $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: 2 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Asm w/ JB & Tape Part Number: 180601-N0502-01b Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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

H HV Harn Asm w/ JB & Tape - Lower Cover 

Asm #6 180601-N0502-01b-07 1

Insert cablesinto lwr cvr, 

assemble upr to lwr cover, snap 

together, reposition

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 212 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.36 $0.14 $0.51 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.51 $0.51 $0.00

8

H HV Harn Asm w/ JB & Tape - Lower Cover 

Asm #7 180601-N0502-01b-08 1

Insert cables (4x) one end and 

insert cables (4x) other end

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 150 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.26 $0.10 $0.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.36 $0.36 $0.00

9

H HV Harn Asm w/ JB & Tape - Lower Cover 

Asm #7 180601-N0502-01b-09 1

Assemble upr to lwr cover, 

snap together & apply tape

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 150 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.26 $0.10 $0.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.36 $0.36 $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 H HV Harn Asm w/ JB & Tape - H Bracket Clip 

Asm 180601-N0502-01b-10 1 Press sleeve into bracket T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 257 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $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 H HV Harn Asm w/ JB & Tape - Lower Cover #5 

& Crush Sleeve 180601-N0502-01b-11 1 Press sleeve into cover T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 225 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.17 $0.07 $0.24 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.24 $0.24 $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 H HV Harn Asm w/ JB & Tape - Lower Cover #6 

& Crush Sleeves 180601-N0502-01b-12 1 Press sleeves (2x) into cover T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 200 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.19 $0.08 $0.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $0.27 $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 H HV Harn Asm w/ JB & Tape - Lower Cover #7 

& Crush Sleeves 180601-N0502-01b-13 1 Press sleeves (3x) into cover T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 200 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.19 $0.08 $0.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $0.27 $0.00

22 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

23 0 180 1 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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

31 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

32 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

33 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

34 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

35 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 H HV Harn Asm w/ JB & Tape - H Bracket Clip 180601-N0502-01b-14 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Nylon6, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 2250 0.25 1 1 0.041 $1.65 $41.48 $28.80 $28.80 $0.07 $0.00 $0.01 $0.09 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.09 $0.09 $0.07

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 H HV Harn Asm w/ JB & Tape - Crush Sleeve 180601-N0502-01b-15 1 Stamp T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS 3600 0.25 1 1 0.011 $0.45 $42.73 $42.91 $42.91 $0.00 $0.00 $0.01 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.02 $0.02 $0.00

4 H HV Harn Asm w/ JB & Tape - Crush Sleeve 180601-N0502-01b-16 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LMC 12000 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.00 $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

H HV Harn Asm w/ JB & Tape - Harn Lwr Cvr 

#4 180601-N0502-01b-17 1 Mold T1 Assembly, Mark-up Applied @ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 2250 0.25 1 1 0.112 $1.74 $41.48 $28.80 $28.80 $0.19 $0.00 $0.01 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $0.19

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 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Asm w/ JB & Tape Part Number: 180601-N0502-01b Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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

H HV Harn Asm w/ JB & Tape - Harn Upr Cover 

#4 180601-N0502-01b-18 1 Mold T1 Assembly, Mark-up Applied @ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 2769 0.25 1 1 0.033 $1.74 $41.48 $28.80 $28.80 $0.06 $0.00 $0.01 $0.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.07 $0.07 $0.06

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

H HV Harn Asm w/ JB & Tape - Harn Lwr Cvr 

#5 180601-N0502-01b-19 1 Mold T1 Assembly, Mark-up Applied @ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, LS 2000 0.25 1 1 0.102 $1.74 $41.48 $151.77 $151.77 $0.18 $0.01 $0.08 $0.26 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.26 $0.26 $0.18

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 H HV Harn Asm w/ JB & Tape - Cvr Lwr #5 

Crush Sleeve Lrg 180601-N0502-01b-20 1 Stamp T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS 3600 0.25 1 1 0.015 $0.45 $42.73 $42.91 $42.91 $0.01 $0.00 $0.01 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.02 $0.02 $0.01

12 H HV Harn Asm w/ JB & Tape - Cvr Lwr #5 

Crush Sleeve Lrg 180601-N0502-01b-21 1 Wash T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LMC 9600 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.00 $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 H HV Harn Asm w/ JB & Tape - Harn Upr Cvr 180601-N0502-01b-22 1 Mold T1 Assembly, Mark-up Applied 14 Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, LS 2400 0.25 1 1 0.111 $1.74 $41.48 $151.77 $151.77 $0.19 $0.00 $0.06 $0.26 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.26 $0.26 $0.19 H HV Harn Asm w/ JB & Tape - Harn Upr Cvr 

#5 180601-N0502-01b-22 1 Mold T1 Assembly, Mark-up Applied @ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, LS 2400 0.25 1 1 0.111 $1.74 $41.48 $151.77 $151.77 $0.19 $0.00 $0.06 $0.26 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.26 $0.26 $0.19

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 H HV Harn Asm w/ JB & Tape - Harn Lwr Cvr 

#6 180601-N0502-01b-23 1 Mold T1 Assembly, Mark-up Applied @ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, LS 2250 0.25 1 1 0.121 $1.74 $41.48 $151.77 $151.77 $0.21 $0.00 $0.07 $0.28 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.28 $0.28 $0.21

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 H HV Harn Asm w/ JB & Tape - Cvr Lwr #6 

Crush Sleeve Lrg 180601-N0502-01b-24 2 Stamp T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS 3600 0.25 1 1 0.015 $0.45 $42.73 $42.91 $42.91 $0.01 $0.00 $0.01 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.02 $0.04 $0.01

19 H HV Harn Asm w/ JB & Tape - Cvr Lwr #6 

Crush Sleeve Lrg 180601-N0502-01b-25 1 Wash T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LMC 9600 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.00 $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 H HV Harn Asm w/ JB & Tape - Harn Upr Cvr 

#6 180601-N0502-01b-26 1 Mold T1 Assembly, Mark-up Applied @ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, LS 2250 0.25 1 1 0.070 $1.74 $41.48 $151.77 $151.77 $0.12 $0.00 $0.07 $0.19 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.19 $0.19 $0.12

22 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

23 H HV Harn Asm w/ JB & Tape - Harn Lwr Cvr 

#7 180601-N0502-01b-27 1 Mold T1 Assembly, Mark-up Applied @ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS 1200 0.25 1 1 0.440 $1.74 $41.48 $90.59 $90.59 $0.77 $0.01 $0.08 $0.85 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.85 $0.85 $0.77

24 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

25 H HV Harn Asm w/ JB & Tape - Cvr Lwr #7 

Crush Sleeve Lrg 180601-N0502-01b-28 3 Stamp T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS 3600 0.25 1 1 0.015 $0.45 $42.73 $42.91 $42.91 $0.01 $0.00 $0.01 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.02 $0.06 $0.02

26 H HV Harn Asm w/ JB & Tape - Cvr Lwr #7 

Crush Sleeve Lrg 180601-N0502-01b-29 1 Wash T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LMC 9600 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.00 $0.00 $0.00

27 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

28 H HV Harn Asm w/ JB & Tape - Harn Upr Cvr 

#7 180601-N0502-01b-30 1 Mold T1 Assembly, Mark-up Applied @ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS 1200 0.25 1 1 0.070 $1.74 $41.48 $90.59 $90.59 $0.12 $0.01 $0.08 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $0.12

29 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

30 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 Black Duct Tape - 1"W 180601-N0502-01b-31 1.708 S $0.00 $0.02 $0.00 $0.03 $0.03

2 0 $0.00 $0.00 $0.00 $0.00 $0.00

3 Orange Tape - 5/8"W 180601-N0502-01b-32 0.833 S $0.00 $0.01 $0.00 $0.01 $0.01

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

5 Wrap Tie - Harness Lower Cover Asm #5 180601-N0502-01b-33 2 S $0.00 $0.01 $0.00 $0.02 $0.02

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

7 Black Duct Tape - 3/4"W 180601-N0502-01b-34 1.167 S $0.00 $0.02 $0.00 $0.02 $0.02

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

9 Black Duct Tape - 3/4"W 180601-N0502-01b-35 1.167 S $0.00 $0.02 $0.00 $0.02 $0.02

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 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.

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

Supplier for Subassembly.

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 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Asm w/ JB & Tape Part Number: 180601-N0502-01b Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$2.06

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

Mark-up $7.38

T1 or OEM Total Manufacturing Cost: $2.06 $3.46 $1.87 $7.38 $0.00 $0.00 $0.00 $0.00 $0.00 $7.38

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 ----- ----- ----- $0.04 $0.48 $0.44 $0.18 $1.14

Base Cost Impact to Vehicle: $2.06 $3.46 $1.87 $7.38 $0.04 $0.48 $0.44 $0.18 $1.14 $8.53 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $8.53

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: 

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable Last 5 Years

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/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

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.)

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 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Asm w/ JB & Tape Part Number: 180601-N0502-01b Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

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: 6 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H HV Harn Asm w/ JB & Tape - H Bracket Clip 

Asm 180601-N0502-01b-01

H HV Harn Asm w/ JB & Tape - Black Duct 

Tape 180601-N0502-01b-02

$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

$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

$0.24 $0.09 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Operator unpack harn asm from dunnage, position/orient, install H bracket clip 5 2 10 100 47 4700 96 37.60 85% 113 31.96 26 1 1 22 1.0 1.0

$0.21 $0.08 $0.30 $0.00 $0.00 $0.00 $0.00 $0.00 Operator install black duct tape around H bracket and harness, reposition/orient 5 2 10 100 47 4700 96 37.60 85% 113 31.96 23 1 1 20 1.0 1.0

H HV Harn Asm w/ JB & Tape - Harn Lwr Cvr 

#4 180601-N0502-01b-03

H HV Harn Asm w/ JB & Tape - Harn Upr Cvr 

#4 180601-N0502-01b-04

H HV Harn Asm w/ JB & Tape - Lower Cover 

Asm #5 180601-N0502-01b-05

H HV Harn Asm w/ JB & Tape - Lower Cover 

Asm #5 180601-N0502-01b-06

$0.32 $0.13 $0.45 $0.00 $0.00 $0.00 $0.00 $0.00 Operator install 3 wires in lwr cover, tape wires to cover ends, install remaining 3 wires 5 2 10 100 47 4700 96 37.60 85% 113 31.96 34 1 1 30 1.0 1.0

$0.24 $0.09 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Operator install upper cover & snap tp lower cover, reposition to next area of harness for assembly 5 2 10 100 47 4700 96 37.60 85% 113 31.96 23 1 1 22 1.0 1.0

$0.45 $0.18 $0.62 $0.00 $0.00 $0.00 $0.00 $0.00 Operator installs 2 wires in lwr cover, wrap ties (2x) wires to cover body (near ends) & trims ties to length 5 2 10 100 47 4700 96 37.60 85% 113 31.96 46 1 1 42 1.0 2.0

$0.34 $0.13 $0.48 $0.00 $0.00 $0.00 $0.00 $0.00 Operator installs upper cover onto lower cover, covers are snapped together (8 points), black duct tape 

secures cover halves together, reposition harn for next components 5 2 10 100 47 4700 96 37.60 85% 113 31.96 32 1 1 32 1.0 2.0

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

H HV Harn Asm w/ JB & Tape - Lower Cover 

Asm #6 180601-N0502-01b-07

H HV Harn Asm w/ JB & Tape - Lower Cover 

Asm #7 180601-N0502-01b-08

H HV Harn Asm w/ JB & Tape - Lower Cover 

Asm #7 180601-N0502-01b-09

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

$0.36 $0.14 $0.51 $0.00 $0.00 $0.00 $0.00 $0.00 Operator places wires (4x) into lower cover, installs upper cover onto lower cover, covers are snapped 

together (6 points), reposition harn for next components 5 2 10 100 47 4700 96 37.60 85% 113 31.96 38 1 1 34 1.0 2.0

$0.26 $0.10 $0.36 $0.00 $0.00 $0.00 $0.00 $0.00 Operator installs wires (4x) in one end lwr cover & installs wires (4x) into other end lower cover 5 2 10 100 47 4700 96 37.60 85% 113 31.96 26 1 1 24 1.0 1.0

$0.26 $0.10 $0.36 $0.00 $0.00 $0.00 $0.00 $0.00 Operator installs upper cover onto lower cover, covers are snapped together (16 points), black duct tape 

applied to secure cover halves together 5 2 10 100 47 4700 96 37.60 85% 113 31.96 23 1 1 24 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

H HV Harn Asm w/ JB & Tape - H Bracket Clip 

Asm 180601-N0502-01b-10

H HV Harn Asm w/ JB & Tape - Lower Cover #5 

& Crush Sleeve 180601-N0502-01b-11

H HV Harn Asm w/ JB & Tape - Lower Cover #6 

& Crush Sleeves 180601-N0502-01b-12

H HV Harn Asm w/ JB & Tape - Lower Cover #7 

& Crush Sleeves 180601-N0502-01b-13

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

$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

$0.15 $0.06 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 Operator load bracket to fixt & sleeve to press head - cycle and unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 1 1 14 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

$0.17 $0.07 $0.24 $0.00 $0.00 $0.00 $0.00 $0.00 Operator load cover to fixt & sleeve to press head - cycle and unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 1 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

$0.19 $0.08 $0.27 $0.00 $0.00 $0.00 $0.00 $0.00 Operator load cover to fixt & sleeves (2x) to press head (2 position) - cycle and unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 24 1 1 18 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

$0.19 $0.08 $0.27 $0.00 $0.00 $0.00 $0.00 $0.00 Operator load cover to fixt & sleeves (3x) to press head (3 position) - cycle and unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 24 1 1 18 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! 32 1 1 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 $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

H HV Harn Asm w/ JB & Tape - H Bracket Clip 180601-N0502-01b-14

H HV Harn Asm w/ JB & Tape - Crush Sleeve 180601-N0502-01b-15

H HV Harn Asm w/ JB & Tape - Crush Sleeve 180601-N0502-01b-16

H HV Harn Asm w/ JB & Tape - Harn Lwr Cvr 

#4 180601-N0502-01b-17

$0.00 $0.01 $0.09 $0.00 $0.00 $0.00 $0.00 $0.00 200-400 Ton Injection Molding w/ 10 cavity mold for H Bracket Clip, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 1 10 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 $0.01 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 25 Ton Progressive Press, Operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1 1 2 2 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 (Wash, Rinse & Dry), operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 50 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 $0.01 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 200-400 Ton Injection Molding w/ 10 cavity mold for Harness Lower Cover #4, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 1 10 16 1.0 1.0

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

H HV Harn Asm w/ JB & Tape - Harn Upr Cover 

#4 180601-N0502-01b-18

H HV Harn Asm w/ JB & Tape - Harn Lwr Cvr 

#5 180601-N0502-01b-19

H HV Harn Asm w/ JB & Tape - Cvr Lwr #5 

Crush Sleeve Lrg 180601-N0502-01b-20

H HV Harn Asm w/ JB & Tape - Cvr Lwr #5 

Crush Sleeve Lrg 180601-N0502-01b-21

H HV Harn Asm w/ JB & Tape - Harn Upr Cvr 180601-N0502-01b-22

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 $0.01 $0.07 $0.00 $0.00 $0.00 $0.00 $0.00 200-400 Ton Injection Molding w/ 10 cavity mold for Harness Upper Cover #4, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 10 13 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

$0.01 $0.08 $0.26 $0.00 $0.00 $0.00 $0.00 $0.00 400-800 Ton Injection Molding w/ 10 cavity mold for Harness Lower Cover #5, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 18 1 10 18 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 $0.01 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 25 Ton Progressive Press, Operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1 1 2 2 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 (Wash, Rinse & Dry), operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 40 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 $0.06 $0.26 $0.00 $0.00 $0.00 $0.00 $0.00 400-800 Ton Injection Molding w/ 10 cavity mold for Harness Upper Cover #5, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 15 1 10 15 1.0 1.0 H HV Harn Asm w/ JB & Tape - Harn Upr Cvr 

#5 180601-N0502-01b-22

H HV Harn Asm w/ JB & Tape - Harn Lwr Cvr 

#6 180601-N0502-01b-23

H HV Harn Asm w/ JB & Tape - Cvr Lwr #6 

Crush Sleeve Lrg 180601-N0502-01b-24

H HV Harn Asm w/ JB & Tape - Cvr Lwr #6 

Crush Sleeve Lrg 180601-N0502-01b-25

H HV Harn Asm w/ JB & Tape - Harn Upr Cvr 

#6 180601-N0502-01b-26

H HV Harn Asm w/ JB & Tape - Harn Lwr Cvr 

#7 180601-N0502-01b-27

H HV Harn Asm w/ JB & Tape - Cvr Lwr #7 

Crush Sleeve Lrg 180601-N0502-01b-28

H HV Harn Asm w/ JB & Tape - Cvr Lwr #7 

Crush Sleeve Lrg 180601-N0502-01b-29

H HV Harn Asm w/ JB & Tape - Harn Upr Cvr 

#7 180601-N0502-01b-30

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

$0.00 $0.06 $0.26 $0.00 $0.00 $0.00 $0.00 $0.00 400-800 Ton Injection Molding w/ 10 cavity mold for Harness Upper Cover #5, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 15 1 10 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 $0.07 $0.28 $0.00 $0.00 $0.00 $0.00 $0.00 400-800 Ton Injection Molding w/ 10 cavity mold for Harness Lower Cover #6, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 1 10 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

$0.01 $0.02 $0.04 $0.00 $0.00 $0.00 $0.00 $0.00 25 Ton Progressive Press, Operator cycle controls 5 2 10 100 47 4700 191 18.80 85% 225 15.98 1 1 2 2 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 (Wash, Rinse & Dry), operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 40 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 $0.07 $0.19 $0.00 $0.00 $0.00 $0.00 $0.00 400-800 Ton Injection Molding w/ 10 cavity mold for Harness Upper Cover #6, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 1 10 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

$0.01 $0.08 $0.85 $0.00 $0.00 $0.00 $0.00 $0.00 800-1500 Ton Injection Molding w/ 6 cavity mold for Harness Lower Cover #7, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 18 1 6 18 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

$0.01 $0.04 $0.06 $0.00 $0.00 $0.00 $0.00 $0.00 25 Ton Progressive Press, Operator cycle controls 5 2 10 100 47 4700 287 12.53 85% 338 10.65 1 1 2 2 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 (Wash, Rinse & Dry), operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 40 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

$0.01 $0.08 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 800-1500 Ton Injection Molding w/ 6 cavity mold for Harness Upper Cover #7, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 17 1 6 18 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

Black Duct Tape - 1"W 180601-N0502-01b-31

Orange Tape - 5/8"W 180601-N0502-01b-32

Wrap Tie - Harness Lower Cover Asm #5 180601-N0502-01b-33

Black Duct Tape - 3/4"W 180601-N0502-01b-34

Black Duct Tape - 3/4"W 180601-N0502-01b-35

$0.03

$0.00

$0.01

$0.00

$0.02

$0.00

$0.02

$0.00

$0.02

$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: 9 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$3.46 $1.87 $7.38 $0.00 $0.00 $0.00 $0.00 $0.00

$7.38

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: 10 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: 11 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H HV Harn Asm w/ JB & Tape - H Bracket Clip 

Asm 180601-N0502-01b-01

H HV Harn Asm w/ JB & Tape - Black Duct 

Tape 180601-N0502-01b-02

#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! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

164 22.00 1.00

180 20.00 1.00

H HV Harn Asm w/ JB & Tape - Harn Lwr Cvr 

#4 180601-N0502-01b-03

H HV Harn Asm w/ JB & Tape - Harn Upr Cvr 

#4 180601-N0502-01b-04

H HV Harn Asm w/ JB & Tape - Lower Cover 

Asm #5 180601-N0502-01b-05

H HV Harn Asm w/ JB & Tape - Lower Cover 

Asm #5 180601-N0502-01b-06

120 30.00 1.00

164 22.00 1.00

171 21.00 2.00

225 16.00 2.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 12 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

H HV Harn Asm w/ JB & Tape - Lower Cover 

Asm #6 180601-N0502-01b-07

H HV Harn Asm w/ JB & Tape - Lower Cover 

Asm #7 180601-N0502-01b-08

H HV Harn Asm w/ JB & Tape - Lower Cover 

Asm #7 180601-N0502-01b-09

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

212 17.00 2.00

150 24.00 1.00

150 24.00 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

H HV Harn Asm w/ JB & Tape - H Bracket Clip 

Asm 180601-N0502-01b-10

H HV Harn Asm w/ JB & Tape - Lower Cover #5 

& Crush Sleeve 180601-N0502-01b-11

H HV Harn Asm w/ JB & Tape - Lower Cover #6 

& Crush Sleeves 180601-N0502-01b-12

H HV Harn Asm w/ JB & Tape - Lower Cover #7 

& Crush Sleeves 180601-N0502-01b-13

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

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

257 14.00 1.00

#DIV/0! #DIV/0! -

225 16.00 1.00

#DIV/0! #DIV/0! -

200 18.00 1.00

#DIV/0! #DIV/0! -

200 18.00 1.00

#DIV/0! #DIV/0! -

180 20.00 1.00

#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! -

H HV Harn Asm w/ JB & Tape - H Bracket Clip 180601-N0502-01b-14

H HV Harn Asm w/ JB & Tape - Crush Sleeve 180601-N0502-01b-15

H HV Harn Asm w/ JB & Tape - Crush Sleeve 180601-N0502-01b-16

H HV Harn Asm w/ JB & Tape - Harn Lwr Cvr 

#4 180601-N0502-01b-17

2250 1.60 0.25

#DIV/0! #DIV/0! -

3600 1.00 0.25

12000 0.30 0.25

#DIV/0! #DIV/0! -

2250 1.60 0.25

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 13 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

H HV Harn Asm w/ JB & Tape - Harn Upr Cover 

#4 180601-N0502-01b-18

H HV Harn Asm w/ JB & Tape - Harn Lwr Cvr 

#5 180601-N0502-01b-19

H HV Harn Asm w/ JB & Tape - Cvr Lwr #5 

Crush Sleeve Lrg 180601-N0502-01b-20

H HV Harn Asm w/ JB & Tape - Cvr Lwr #5 

Crush Sleeve Lrg 180601-N0502-01b-21

H HV Harn Asm w/ JB & Tape - Harn Upr Cvr 180601-N0502-01b-22

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

2769 1.30 0.25

#DIV/0! #DIV/0! -

2000 1.80 0.25

#DIV/0! #DIV/0! -

3600 1.00 0.25

9600 0.38 0.25

#DIV/0! #DIV/0! -

2400 1.50 0.25 H HV Harn Asm w/ JB & Tape - Harn Upr Cvr 

#5 180601-N0502-01b-22

H HV Harn Asm w/ JB & Tape - Harn Lwr Cvr 

#6 180601-N0502-01b-23

H HV Harn Asm w/ JB & Tape - Cvr Lwr #6 

Crush Sleeve Lrg 180601-N0502-01b-24

H HV Harn Asm w/ JB & Tape - Cvr Lwr #6 

Crush Sleeve Lrg 180601-N0502-01b-25

H HV Harn Asm w/ JB & Tape - Harn Upr Cvr 

#6 180601-N0502-01b-26

H HV Harn Asm w/ JB & Tape - Harn Lwr Cvr 

#7 180601-N0502-01b-27

H HV Harn Asm w/ JB & Tape - Cvr Lwr #7 

Crush Sleeve Lrg 180601-N0502-01b-28

H HV Harn Asm w/ JB & Tape - Cvr Lwr #7 

Crush Sleeve Lrg 180601-N0502-01b-29

H HV Harn Asm w/ JB & Tape - Harn Upr Cvr 

#7 180601-N0502-01b-30

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

2400 1.50 0.25

#DIV/0! #DIV/0! -

2250 1.60 0.25

#DIV/0! #DIV/0! -

3600 1.00 0.25

9600 0.38 0.25

#DIV/0! #DIV/0! -

2250 1.60 0.25

#DIV/0! #DIV/0! -

1200 3.00 0.25

#DIV/0! #DIV/0! -

3600 1.00 0.25

9600 0.38 0.25

#DIV/0! #DIV/0! -

1200 3.00 0.25

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Black Duct Tape - 1"W 180601-N0502-01b-31

Orange Tape - 5/8"W 180601-N0502-01b-32

Wrap Tie - Harness Lower Cover Asm #5 180601-N0502-01b-33

Black Duct Tape - 3/4"W 180601-N0502-01b-34

Black Duct Tape - 3/4"W 180601-N0502-01b-35

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 14 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: 15 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Asm w/ Tape & Conn Part Number: 180601-N0502-03 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 H HV Harn Asm w/ Tape & Conn - Term Base 180601-N0502-01c-01 1

Unpack harn asm, 

position/orient & install term 

through base

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 126 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.61 $0.24 $0.85 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.85 $0.85 $0.00

2

H HV Harn Asm w/ Tape & Conn - Connector 

Asm 180601-N0502-01c-02 1 Assemble term into conn asm T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 120 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.64 $0.25 $0.89 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.89 $0.89 $0.00

3 H HV Harn Asm w/ Tape & Conn - Shield 180601-N0502-01c-03 1

Assemble conn shield (1 of 2) 

to shield base (2x screws)

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 138 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.28 $0.11 $0.39 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.39 $0.39 $0.00

4 H HV Harn Asm w/ Tape & Conn - Shield 180601-N0502-01c-04 1

Assemble conn shield (2 of 2) 

to shield base (2x screws)

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 150 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.26 $0.10 $0.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.36 $0.36 $0.00

5

H HV Harn Asm w/ Tape & Conn - Seals & 

Seats 180601-N0502-01c-05 1

Push Seals & Seats (3x) up into 

conn bas asm

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 164 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.24 $0.09 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

6

H HV Harn Asm w/ Tape & Conn - Seals & 

Seats 180601-N0502-01c-06 1

Push Seals & Seats (3x) up into 

conn bas asm

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 171 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.22 $0.09 $0.31 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.31 $0.31 $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: 2 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Asm w/ Tape & Conn Part Number: 180601-N0502-03 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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

H HV Harn Asm w/ Tape & Conn - Junction 

Block Cover 180601-N0502-01c-07 1 Install cover over block T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 450 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.04 $0.03 $0.08 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.08 $0.08 $0.00

8

H HV Harn Asm w/ Tape & Conn - JB Cover 

Rear 180601-N0502-01c-08 1

Install cover over rear conn 

cover

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 327 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.12 $0.05 $0.16 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.16 $0.16 $0.00

9

H HV Harn Asm w/ Tape & Conn - JB Cover 

Front 180601-N0502-01c-09 1

Install cover over front conn 

cover

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 277 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.14 $0.05 $0.19 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.19 $0.19 $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

8 H HV JB Conn Cover Base Asm 180601-N0502-01c-10 1 Insert seal into base T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 257 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $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 H HV JB Conn Asm - Jumpers 180601-N0502-01c-11 1 Insert jumper term (2x) T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 180 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.21 $0.08 $0.30 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.30 $0.30 $0.00

11 H HV JB Conn Asm - Top & Shield Base 180601-N0502-01c-12 1

Snap top on conn body and 

insert shield base on bottom

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 300 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.13 $0.05 $0.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.18 $0.18 $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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 H HV JB Conn Cover - Base 180601-N0502-01c-13 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. PBT-GF20, Inject. Mold/Cast/Sinter Operator

Inject. Mold, SS

2769 0.25 1 1 0.074 $1.46 $41.48 $16.39 $16.39 $0.11 $0.00 $0.01 $0.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.12 $0.12 $0.11

2 H HV JB Conn Cover - Seal 180601-N0502-01c-14 1 Mold T1 Assembly, Mark-up Applied Thermoset-SBR

Mold/Cast/Sinter Operator

Inject. Mold, SS

2 H HV JB Conn Cover - Seal 180601-N0502-01c-14 1 Mold 1091 0.25 1 1 0.011 $1.32 $41.48 $16.39 $16.39 $0.01 $0.01 $0.02 $0.04 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.04 $0.04 $0.01 T1 Assembly, Mark-up Applied 

@ Bottom. Mold/Cast/Sinter Operator 1091 0.25 1 1 0.011 $1.32 $41.48 $16.39 $16.39 $0.01 $0.01 $0.02 $0.04 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.04 $0.04 $0.01

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 H HV JB Conn Asm - Body 180601-N0502-01c-15 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. PBT-GF20, Inject. Mold/Cast/Sinter Operator

Inject. Mold, SS

3000 0.25 1 1 0.066 $1.46 $41.48 $16.39 $16.39 $0.10 $0.00 $0.01 $0.11 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.11 $0.11 $0.10

5 H HV JB Conn Asm - Jumper Terminal 180601-N0502-01c-16 1 Stamp T1 Assembly, Mark-up Applied 

@ Bottom.

Copper-Pure, Wire

Cut/Punch/Forming Operator Stamp/Form, SS 3600 0.25 1 1 0.013 $2.45 $42.73 $42.91 $42.91 $0.03 $0.00 $0.01 $0.05 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.05 $0.05 $0.03

6 H HV JB Conn Asm - Jumper Terminal 180601-N0502-01c-17 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LMC 4800 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.01 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.01 $0.01 $0.00

7 H HV JB Conn Asm - Top 180601-N0502-01c-18 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. PBT-GF20, Inject. Mold/Cast/Sinter Operator

Inject. Mold, SS

4500 0.25 1 1 0.018 $1.46 $41.48 $16.39 $16.39 $0.03 $0.00 $0.00 $0.03 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.03 $0.03 $0.03

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 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Asm w/ Tape & Conn Part Number: 180601-N0502-03 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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 H HV JB Conn Shield Base 180601-N0502-01c-19 1 Die Cast T1 Assembly, Mark-up Applied 

@ Bottom.

Zinc Zmk#3

Mold/Cast/Sinter Operator Diecast, SS 2274 0.25 1 1 0.039 $1.24 $41.48 $70.80 $70.80 $0.05 $0.00 $0.03 $0.08 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.08 $0.08 $0.05

9 H HV JB Conn Shield Base 180601-N0502-01c-20 1 Trim Press T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Trim Press, XSS 450 0.5 1 1 0.000 $0.00 $42.73 $12.69 $12.69 $0.00 $0.05 $0.03 $0.08 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.08 $0.08 $0.00

10 H HV JB Conn Shield Base 180601-N0502-01c-21 1 Drill & Tap (2x) T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Drilling/Boring Operator Dedicated Machining Center - Single Station, LC, Base 180 1 1 1 0.000 $0.00 $38.69 $30.38 $30.38 $0.00 $0.21 $0.17 $0.38 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.38 $0.38 $0.00

11 H HV JB Conn Shield Base 180601-N0502-01c-22 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LMC 2400 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.01 $0.01 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.01 $0.01 $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 H HV JB Conn Shield 180601-N0502-01c-23 2 Die Cast T1 Assembly, Mark-up Applied 

@ Bottom.

Zinc Zmk#3

Mold/Cast/Sinter Operator Diecast, SS 2160 0.25 1 1 0.071 $1.24 $41.48 $70.80 $70.80 $0.09 $0.00 $0.03 $0.13 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.13 $0.25 $0.18

14 H HV JB Conn Shield 180601-N0502-01c-24 2 Trim Press T1 Assembly, Mark-up Applied 14 H HV JB Conn Shield 180601-N0502-01c-24 2 Trim Press Not Applicable Cut/Punch/Forming Operator Trim Press, XSS 450 0.5 1 1 0.000 $0.00 $42.73 $12.69 $12.69 $0.00 $0.05 $0.03 $0.08 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.08 $0.15 $0.00 T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Trim Press, XSS 450 0.5 1 1 0.000 $0.00 $42.73 $12.69 $12.69 $0.00 $0.05 $0.03 $0.08 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.08 $0.15 $0.00

15 H HV JB Conn Shield 180601-N0502-01c-25 2 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LMC 2400 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.01 $0.01 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.01 $0.03 $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 H HV JB Conn Asm - Conn Cover 180601-N0502-01c-26 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. PBT-GF20, Inject. Mold/Cast/Sinter Operator

Inject. Mold, SMS

2250 0.25 1 1 0.119 $1.46 $41.48 $28.80 $28.80 $0.17 $0.00 $0.01 $0.19 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.19 $0.19 $0.17

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 H HV JB Conn Asm - JB Rear Cover 180601-N0502-01c-27 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator

Inject. Mold, LS

2118 0.25 1 1 0.140 $1.74 $41.48 $151.77 $151.77 $0.24 $0.00 $0.07 $0.32 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.32 $0.32 $0.24

20 H HV JB Conn Asm - JB Front Cover 180601-N0502-01c-28 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator

Inject. Mold, SMS

2118 0.25 1 1 0.064 $1.74 $41.48 $28.80 $28.80 $0.11 $0.00 $0.01 $0.13 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.13 $0.13 $0.11

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 H Screw, HV JB Conn Shield 180601-N0502-01c-29 2 (no comm price - estimated) S $0.00 $0.06 $0.00 $0.12 $0.12

2 H Screw, HV JB Conn Shield 180601-N0502-01c-30 2 (no comm price - estimated) S $0.00 $0.06 $0.00 $0.12 $0.12

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

4 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 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 $0.00

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

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

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.

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

Supplier for Subassembly.

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 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Asm w/ Tape & Conn Part Number: 180601-N0502-03 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$1.27

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

Mark-up $6.45

T1 or OEM Total Manufacturing Cost: $1.27 $3.46 $1.72 $6.45 $0.00 $0.00 $0.00 $0.00 $0.00 $6.45

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 $0.42 $0.39 $0.16 $1.00

Base Cost Impact to Vehicle: $1.27 $3.46 $1.72 $6.45 $0.03 $0.42 $0.39 $0.16 $1.00 $7.45 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $7.45

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 Tier Pad Tier Pads Divider Pads, Divider Pads Other #1 Other #1 Other #2 Other #2 Other #3 Other #3 

PACKAGING CALCULATIONS: 

Packaging Type: 

Part Size: 

Parts/Layer: 

Number of Layers: 

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable 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

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

8.29268

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: 5 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Asm w/ Tape & Conn Part Number: 180601-N0502-03 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

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 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H HV Harn Asm w/ Tape & Conn - Term Base 180601-N0502-01c-01

H HV Harn Asm w/ Tape & Conn - Connector 

Asm 180601-N0502-01c-02

$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

$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

$0.61 $0.24 $0.85 $0.00 $0.00 $0.00 $0.00 $0.00 Operator unpack harn asm from dunnage, position/orient for harn, install term (x6) through conn cover 

base asm 5 2 10 100 47 4700 96 37.60 85% 113 31.96 68 1 1 57 1.0 2.0

$0.64 $0.25 $0.89 $0.00 $0.00 $0.00 $0.00 $0.00 Operator install term (x6) into conn asm 5 2 10 100 47 4700 96 37.60 85% 113 31.96 73 1 1 60 1.0 2.0

H HV Harn Asm w/ Tape & Conn - Shield 180601-N0502-01c-03

H HV Harn Asm w/ Tape & Conn - Shield 180601-N0502-01c-04

H HV Harn Asm w/ Tape & Conn - Seals & 

Seats 180601-N0502-01c-05

H HV Harn Asm w/ Tape & Conn - Seals & 

Seats 180601-N0502-01c-06

$0.28 $0.11 $0.39 $0.00 $0.00 $0.00 $0.00 $0.00 Operator loads & installs (2x) screws w/ screw gun assist tool 5 2 10 100 47 4700 96 37.60 85% 113 31.96 38 1 1 26 1.0 1.0

$0.26 $0.10 $0.36 $0.00 $0.00 $0.00 $0.00 $0.00 Operator loads & installs (2x) screws w/ screw gun assist tool 5 2 10 100 47 4700 96 37.60 85% 113 31.96 36 1 1 24 1.0 1.0

$0.24 $0.09 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Operator slides seals & seats (3x) to conn base and pushes them to depth to seat in conn base 5 2 10 100 47 4700 96 37.60 85% 113 31.96 27 1 1 22 1.0 1.0

$0.22 $0.09 $0.31 $0.00 $0.00 $0.00 $0.00 $0.00 Operator slides seals & seats (3x) to conn base and pushes them to depth to seat in conn base 5 2 10 100 47 4700 96 37.60 85% 113 31.96 25 1 1 21 1.0 1.0

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

H HV Harn Asm w/ Tape & Conn - Junction 

Block Cover 180601-N0502-01c-07

H HV Harn Asm w/ Tape & Conn - JB Cover 

Rear 180601-N0502-01c-08

H HV Harn Asm w/ Tape & Conn - JB Cover 

Front 180601-N0502-01c-09

H HV JB Conn Cover Base Asm 180601-N0502-01c-10

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

$0.04 $0.03 $0.08 $0.00 $0.00 $0.00 $0.00 $0.00 Operator pushes junction block cover over terminals and snaps together 5 2 10 100 47 4700 96 37.60 85% 113 31.96 8 1 1 8 1.0 1.0

$0.12 $0.05 $0.16 $0.00 $0.00 $0.00 $0.00 $0.00 Operator fits JB rear cover over connector cover 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 1 1 11 1.0 1.0

$0.14 $0.05 $0.19 $0.00 $0.00 $0.00 $0.00 $0.00 Operator fits JB front cover over connector cover & snaps together with rear cover 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 $0.00 $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

$0.15 $0.06 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 Operator insert seal into conn cover base 5 2 10 100 47 4700 96 37.60 85% 113 31.96 15 1 1 14 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

H HV JB Conn Asm - Jumpers 180601-N0502-01c-11

H HV JB Conn Asm - Top & Shield Base 180601-N0502-01c-12

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

H HV JB Conn Cover - Base 180601-N0502-01c-13

H HV JB Conn Cover - Seal 180601-N0502-01c-14

$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

$0.21 $0.08 $0.30 $0.00 $0.00 $0.00 $0.00 $0.00 Operator insert jumper terminals (2x) into conn body 5 2 10 100 47 4700 96 37.60 85% 113 31.96 21 1 1 20 1.0 1.0

$0.13 $0.05 $0.18 $0.00 $0.00 $0.00 $0.00 $0.00 Operator insert conn top on body and insert shield base into bottom 5 2 10 100 47 4700 96 37.60 85% 113 31.96 10 1 1 12 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

$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 $0.01 $0.12 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 10 cavity mold for JB Conn Cover Base, operator cycle controls (used 

PBT-GF20 Mat'l instead of PBT-GF15) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 10 13 1.0 1.0

H HV JB Conn Cover - Seal 180601-N0502-01c-14 $0.01 $0.02 $0.04 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 10 cavity mold for JB Seal Conn Cover, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 33 1 10 33 1.0 1.0

H HV JB Conn Asm - Body 180601-N0502-01c-15

H HV JB Conn Asm - Jumper Terminal 180601-N0502-01c-16

H HV JB Conn Asm - Jumper Terminal 180601-N0502-01c-17

H HV JB Conn Asm - Top 180601-N0502-01c-18

$0.01 $0.02 $0.04 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 10 cavity mold for JB Seal Conn Cover, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 33 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 $0.01 $0.11 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 10 cavity mold for JB Conn Cover Base, operator cycle controls (used 

PBT-GF20 Mat'l instead of PBT-GF15) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 12 1 10 12 1.0 1.0

$0.00 $0.01 $0.05 $0.00 $0.00 $0.00 $0.00 $0.00 25 Ton press - progressive, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1 1 2 2 1.0 1.0

$0.00 $0.00 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 (Wash, Rinse & Dry), operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 20 15 1.0 1.0

$0.00 $0.00 $0.03 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 10 cavity mold for JB Conn Cover Top, operator cycle controls (used 

PBT-GF20 Mat'l instead of PBT-GF15) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 8 1 10 8 1.0 1.0

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

H HV JB Conn Shield Base 180601-N0502-01c-19

H HV JB Conn Shield Base 180601-N0502-01c-20

H HV JB Conn Shield Base 180601-N0502-01c-21

H HV JB Conn Shield Base 180601-N0502-01c-22

H HV JB Conn Shield 180601-N0502-01c-23

H HV JB Conn Shield 180601-N0502-01c-24

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 $0.03 $0.08 $0.00 $0.00 $0.00 $0.00 $0.00 0-500 Ton Die Cast w/ 12 cavity mold, operator cycle controls 

(Created Zinc Zemak #3 Mat't Spec category @ bottom of RM sheet) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 19 1 12 19 1.0 1.0

$0.05 $0.03 $0.08 $0.00 $0.00 $0.00 $0.00 $0.00 Small trim press w/ operator load/unload & cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 6 1 1 8 1.0 1.0

$0.21 $0.17 $0.38 $0.00 $0.00 $0.00 $0.00 $0.00 Small semi-automated drill press sta - drill & tap (2x) holes, operator load/unload & cycle 5 2 10 100 47 4700 96 37.60 85% 113 31.96 22 1 1 20 1.0 1.0

$0.00 $0.01 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 (Wash, Rinse & Dry), operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 - 10 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

$0.01 $0.07 $0.25 $0.00 $0.00 $0.00 $0.00 $0.00 0-500 Ton Die Cast w/ 12 cavity mold, operator cycle controls (Created 

Zinc Zemak #3 Mat't Spec category @ bottom of RM sheet) 5 2 10 100 47 4700 191 18.80 85% 225 15.98 20 1 12 20 1.0 1.0

H HV JB Conn Shield 180601-N0502-01c-24 $0.09 $0.06 $0.15 $0.00 $0.00 $0.00 $0.00 $0.00 Small trim press w/ operator load/unload & cycle controls 5 2 10 100 47 4700 191 18.80 85% 225 15.98 6 1 1 8 1.0 1.0

H HV JB Conn Shield 180601-N0502-01c-25

H HV JB Conn Asm - Conn Cover 180601-N0502-01c-26

H HV JB Conn Asm - JB Rear Cover 180601-N0502-01c-27

H HV JB Conn Asm - JB Front Cover 180601-N0502-01c-28

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

H Screw, HV JB Conn Shield 180601-N0502-01c-29

H Screw, HV JB Conn Shield 180601-N0502-01c-30

$0.09 $0.06 $0.15 $0.00 $0.00 $0.00 $0.00 $0.00 Small trim press w/ operator load/unload & cycle controls 5 2 10 100 47 4700 191 18.80 85% 225 15.98 6 1 1 8 1.0 1.0

$0.01 $0.02 $0.03 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 (Wash, Rinse & Dry), operator load/unload 5 2 10 100 47 4700 191 18.80 85% 225 15.98 13 - 10 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 $0.01 $0.19 $0.00 $0.00 $0.00 $0.00 $0.00 200-400 Ton Injection Molding w/ 10 cavity mold for Junction Block Cover, operator cycle controls 

(used PBT-GF20 Mat'l instead of PBT-GF15) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 1 10 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 $0.07 $0.32 $0.00 $0.00 $0.00 $0.00 $0.00 400-800 Ton Injection Molding w/ 10 cavity mold for JB Rear Cover, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 17 1 10 17 1.0 1.0

$0.00 $0.01 $0.13 $0.00 $0.00 $0.00 $0.00 $0.00 200-400 Ton Injection Molding w/ 10 cavity mold for JB Front Cover, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 17 1 10 17 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

$0.12

$0.12

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$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: 9 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$3.46 $1.72 $6.45 $0.00 $0.00 $0.00 $0.00 $0.00

$6.45

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: 10 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: 11 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H HV Harn Asm w/ Tape & Conn - Term Base 180601-N0502-01c-01

H HV Harn Asm w/ Tape & Conn - Connector 

Asm 180601-N0502-01c-02

#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! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

126 28.50 2.00

120 30.00 2.00

H HV Harn Asm w/ Tape & Conn - Shield 180601-N0502-01c-03

H HV Harn Asm w/ Tape & Conn - Shield 180601-N0502-01c-04

H HV Harn Asm w/ Tape & Conn - Seals & 

Seats 180601-N0502-01c-05

H HV Harn Asm w/ Tape & Conn - Seals & 

Seats 180601-N0502-01c-06

138 26.00 1.00

150 24.00 1.00

164 22.00 1.00

171 21.00 1.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 12 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

H HV Harn Asm w/ Tape & Conn - Junction 

Block Cover 180601-N0502-01c-07

H HV Harn Asm w/ Tape & Conn - JB Cover 

Rear 180601-N0502-01c-08

H HV Harn Asm w/ Tape & Conn - JB Cover 

Front 180601-N0502-01c-09

H HV JB Conn Cover Base Asm 180601-N0502-01c-10

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

450 8.00 0.50

327 11.00 1.00

277 13.00 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

257 14.00 1.00

#DIV/0! #DIV/0! -

H HV JB Conn Asm - Jumpers 180601-N0502-01c-11

H HV JB Conn Asm - Top & Shield Base 180601-N0502-01c-12

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

H HV JB Conn Cover - Base 180601-N0502-01c-13

H HV JB Conn Cover - Seal 180601-N0502-01c-14

#DIV/0! #DIV/0! -

180 20.00 1.00

300 12.00 1.00

#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! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

2769 1.30 0.25

H HV JB Conn Cover - Seal 180601-N0502-01c-14 1091 3.30 0.25

H HV JB Conn Asm - Body 180601-N0502-01c-15

H HV JB Conn Asm - Jumper Terminal 180601-N0502-01c-16

H HV JB Conn Asm - Jumper Terminal 180601-N0502-01c-17

H HV JB Conn Asm - Top 180601-N0502-01c-18

1091 3.30 0.25

#DIV/0! #DIV/0! -

3000 1.20 0.25

3600 1.00 0.25

4800 0.75 0.25

4500 0.80 0.25

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 13 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

H HV JB Conn Shield Base 180601-N0502-01c-19

H HV JB Conn Shield Base 180601-N0502-01c-20

H HV JB Conn Shield Base 180601-N0502-01c-21

H HV JB Conn Shield Base 180601-N0502-01c-22

H HV JB Conn Shield 180601-N0502-01c-23

H HV JB Conn Shield 180601-N0502-01c-24

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

2274 1.58 0.25

450 8.00 0.50

180 20.00 1.00

2400 1.50 0.25

#DIV/0! #DIV/0! -

2160 1.67 0.25

H HV JB Conn Shield 180601-N0502-01c-24 450 8.00 0.50

H HV JB Conn Shield 180601-N0502-01c-25

H HV JB Conn Asm - Conn Cover 180601-N0502-01c-26

H HV JB Conn Asm - JB Rear Cover 180601-N0502-01c-27

H HV JB Conn Asm - JB Front Cover 180601-N0502-01c-28

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

H Screw, HV JB Conn Shield 180601-N0502-01c-29

H Screw, HV JB Conn Shield 180601-N0502-01c-30

450 8.00 0.50

2400 1.50 0.25

#DIV/0! #DIV/0! -

2250 1.60 0.25

#DIV/0! #DIV/0! -

2118 1.70 0.25

2118 1.70 0.25

#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: 14 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: 15 of 15 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 18 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Asm w/ Tape & Terminals Part Number: 180601-N0502-01d Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 H HV Cable Boot 180601-N0502-01d-01 1

Assemble to H HV Harn Misc 

Hardware Asm

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 164 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.24 $0.09 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

2 H HV Cable Boot Mount Asm 180601-N0502-01d-02 1

Assemble to H HV Harn Misc 

Hardware Asm Boot (slide over 

cables)

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 150 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.26 $0.10 $0.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.36 $0.36 $0.00

3 H HV Cable Boot Mount Asm - Wrap Tie 180601-N0502-01d-03 1

Wrap Tie Harness Asm to Boot 

Mount

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 257 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $0.00

4 H HV Medium Conn Asm AC 180601-N0502-01d-04 1

Assemble to Harness end (slide 

over terminals)

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 164 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.24 $0.09 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

5 H HV Medium Conn Asm AC - Seals 180601-N0502-01d-05 1 Slide seals into connector body T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 164 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.24 $0.09 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

6 H HV Medium Conn Asm AC - Shields 180601-N0502-01d-06 1

Push shields into connector 

body

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 257 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $0.00

7 H HV Medium Conn Asm AC - TPA & SC 180601-N0502-01d-07 1

Lock connector to harness (w/ 

TPAs) connect small to med 

connector bodies

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 138 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.28 $0.11 $0.39 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.39 $0.39 $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: 2 of 18 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Asm w/ Tape & Terminals Part Number: 180601-N0502-01d Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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 H HV Cable Clamp Curve Asm 180601-N0502-01d-08 1

Snap halves together & 

reposition harness for next 

connector

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 150 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.26 $0.10 $0.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.36 $0.36 $0.00

9 H HV Medium Conn Asm DC-DC 180601-N0502-01d-09 1

Assemble to Harness end (slide 

over terminals)

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 164 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.24 $0.09 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

10 H HV Medium Conn Asm DC-DC - Seals 180601-N0502-01d-10 1 Slide seals into connector body T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 164 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.24 $0.09 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

11 H HV Medium Conn Asm DC-DC - Shields 180601-N0502-01d-11 1

Push shields into connector 

body

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 257 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $0.00

12 H HV Medium Conn Asm DC-DC - TPA & SC 180601-N0502-01d-12 1

Lock connector to harness (w/ 

TPAs) connect small to med 

connector bodies

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 138 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.28 $0.11 $0.39 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.39 $0.39 $0.00

13 H HV Cable Clamp Straight Asm 180601-N0502-01d-13 1

Snap halves together & 

reposition harness for next 

connector

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 150 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.26 $0.10 $0.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.36 $0.36 $0.00

14 H HV Medium Conn Asm BEC 180601-N0502-01d-14 1

Assemble to Harness end (slide 

over terminals)

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 164 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.24 $0.09 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

15 H HV Medium Conn Asm BEC - Seals 180601-N0502-01d-15 1 Slide seals into connector body T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 164 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.24 $0.09 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

16 H HV Medium Conn Asm BEC - Shields 180601-N0502-01d-16 1

Push shields into connector 

body

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 257 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $0.00

17 H HV Medium Conn Asm BEC - TPA & SC 180601-N0502-01d-17 1

Lock connector to harness (w/ 

TPAs) connect small to med 

connector bodies

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 138 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.28 $0.11 $0.39 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.39 $0.39 $0.00

18 H HV Medium Conn Asm BEC - Conn Caps 180601-N0502-01d-18 1

Snap lock 2 Conn caps to ends 

of Med Conn body & reposition 

harn for next conn

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 150 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.26 $0.10 $0.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.36 $0.36 $0.00

19 H HV Large Conn Asm BEC 180601-N0502-01d-19 1

Assemble to Harness end (slide 

over terminals)

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 144 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.27 $0.10 $0.37 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.37 $0.37 $0.00

20 H HV Large Conn Asm BEC - Seals 180601-N0502-01d-20 1 Slide seals into connector body T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 164 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.24 $0.09 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

21 H HV Large Conn Asm BEC - Shields 180601-N0502-01d-21 1

Push shields into connector 

body

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 257 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $0.00

22 H HV Large Conn Asm BEC - Lock 180601-N0502-01d-22 1 Push Lock over connector body T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 450 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.04 $0.03 $0.08 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.08 $0.08 $0.00

23 H HV Lrg Conn BEC Clamp Asm 180601-N0502-01d-23 1 Snap clamp halves together T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 150 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.26 $0.10 $0.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.36 $0.36 $0.00

24 H HV Large Conn Asm BEC - TPA 180601-N0502-01d-24 1

Lock connector to harness (w/ 

TPA) & reposition harness for 

next connector

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 164 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.24 $0.09 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

25 H HV Large Conn Asm TCM 180601-N0502-01d-25 1

Assemble to Harness end (slide 

over terminals)

T1 Assembly, Mark-up Applied 

@ Bottom. 25 H HV Large Conn Asm TCM 180601-N0502-01d-25 1 Not Applicable General Assembly Mech Assembly, LC, Base 144 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.27 $0.10 $0.37 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.37 $0.37 $0.00 over terminals) @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 144 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.27 $0.10 $0.37 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.37 $0.37 $0.00

26 H HV Large Conn Asm TCM - Seals 180601-N0502-01d-26 1 Slide seals into connector body T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 164 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.24 $0.09 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

27 H HV Large Conn Asm TCM - Shields 180601-N0502-01d-27 1

Push shields into connector 

body

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 257 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $0.00

28 H HV Large Conn Asm TCM - Lock 180601-N0502-01d-28 1 Push Lock over connector body T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 450 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.04 $0.03 $0.08 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.08 $0.08 $0.00

29 H HV Lrg Conn TCM Clamp Asm 180601-N0502-01d-29 1 Snap clamp halves together T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 150 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.26 $0.10 $0.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.36 $0.36 $0.00

24 H HV Large Conn Asm TCM - TPA 180601-N0502-01d-30 1

Lock connector to harness (w/ 

TPA) & reposition harness for 

next connector

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 257 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $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: 3 of 18 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Asm w/ Tape & Terminals Part Number: 180601-N0502-01d Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

24 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

25 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

26 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

27 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

28 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

29 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

30 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

31 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)

T1 Assembly, Mark-up Applied 1 H HV Cable Boot 180601-N0502-01d-31 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Thermoset-NR Mold/Cast/Sinter Operator Inject. Mold, MLS 5143 0.25 1 1 0.360 $2.14 $41.48 $90.59 $90.59 $0.77 $0.00 $0.02 $0.79 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.79 $0.79 $0.77

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 H HV Cable Boot Mount Asm - Body 180601-N0502-01d-32 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator

Inject. Mold, LS

960 0.5 1 1 0.105 $1.74 $41.48 $151.77 $151.77 $0.18 $0.02 $0.16 $0.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.36 $0.36 $0.18

4 H HV Cable Boot Mount Asm 180601-N0502-01d-33 1

Insert bolts (x3ea) into mold 

cavities

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Mold/Cast/Sinter Operator Dedicated Machining Center - Single Station, MHC, Base 1200 0.5 1 1 0.000 $0.00 $41.48 $53.25 $53.25 $0.00 $0.02 $0.04 $0.06 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.06 $0.06 $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 H HV Medium Conn Asm AC - Body 180601-N0502-01d-34 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom.

Nylon6, Inject.

Mold/Cast/Sinter Operator

Inject. Mold, LS

2700 0.25 1 1 0.072 $1.65 $41.48 $151.77 $151.77 $0.12 $0.00 $0.06 $0.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.18 $0.18 $0.12

7 H HV Medium Conn Asm AC - Shield 180601-N0502-01d-35 1 Stamp T1 Assembly, Mark-up Applied 

@ Bottom.

S-Steel-304, Tube

Cut/Punch/Forming Operator Stamp/Form, SS 2400 0.25 1 1 0.090 $1.65 $42.73 $42.91 $42.91 $0.15 $0.00 $0.02 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.17 $0.15

8 H HV Medium Conn Asm AC - Shield 180601-N0502-01d-36 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LMC 12000 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.00 $0.00 $0.00

9 H HV Medium Conn Asm AC - Seal 180601-N0502-01d-37 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Thermoset-SBR Mold/Cast/Sinter Operator

Inject. Mold, LS

1867 0.25 1 1 0.004 $1.32 $41.48 $151.77 $151.77 $0.01 $0.01 $0.08 $0.09 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.09 $0.09 $0.01

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 H HV Cable Clamp Curved - Base 180601-N0502-01d-38 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom.

Nylon66, Inject.

Mold/Cast/Sinter Operator

Inject. Mold, LS

3927 0.25 1 1 0.013 $1.74 $41.48 $151.77 $151.77 $0.02 $0.00 $0.04 $0.06 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.06 $0.06 $0.02

12 H HV Cable Clamp Curved - Cover 180601-N0502-01d-39 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom.

Nylon66, Inject.

Mold/Cast/Sinter Operator

Inject. Mold, LS

3927 0.25 1 1 0.014 $1.74 $41.48 $151.77 $151.77 $0.03 $0.00 $0.04 $0.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.07 $0.07 $0.03

13 0

T1 Assembly, Mark-up Applied 

@ Bottom. ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0.00% #N/A #N/A $0.00 $0.00

14 H HV Medium Conn Asm DC-DC - Body 180601-N0502-01d-40 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom.

Nylon6, Inject.

Mold/Cast/Sinter Operator

Inject. Mold, LS

2700 0.25 1 1 0.072 $1.65 $41.48 $151.77 $151.77 $0.12 $0.00 $0.06 $0.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.18 $0.18 $0.12

15 H HV Medium Conn Asm DC-DC - Shield 180601-N0502-01d-41 1 Stamp T1 Assembly, Mark-up Applied 

@ Bottom.

S-Steel-304, Tube

Cut/Punch/Forming Operator Stamp/Form, SS 2400 0.25 1 1 0.090 $1.65 $42.73 $42.91 $42.91 $0.15 $0.00 $0.02 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.17 $0.15

16 H HV Medium Conn Asm DC-DC - Shield 180601-N0502-01d-42 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LMC 12000 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.00 $0.00 $0.00

17 H HV Medium Conn Asm DC-DC - Seal 180601-N0502-01d-43 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Thermoset-SBR Mold/Cast/Sinter Operator

Inject. Mold, LS

1867 0.25 1 1 0.004 $1.32 $41.48 $151.77 $151.77 $0.01 $0.01 $0.08 $0.09 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.09 $0.09 $0.01

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 H HV Cable Clamp Straight - Base 180601-N0502-01d-44 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom.

Nylon66, Inject.

Mold/Cast/Sinter Operator

Inject. Mold, LS

3927 0.25 1 1 0.013 $1.74 $41.48 $151.77 $151.77 $0.02 $0.00 $0.04 $0.06 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.06 $0.06 $0.02

20 H HV Cable Clamp Straight - Cover 180601-N0502-01d-45 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom.

Nylon66, Inject.

Mold/Cast/Sinter Operator

Inject. Mold, LS

3927 0.25 1 1 0.014 $1.74 $41.48 $151.77 $151.77 $0.03 $0.00 $0.04 $0.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.07 $0.07 $0.03

21 0

T1 Assembly, Mark-up Applied 

@ Bottom. ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0.00% #N/A #N/A $0.00 $0.00

22 H HV Medium Conn Asm BEC - Body 180601-N0502-01d-46 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom.

Nylon6, Inject.

Mold/Cast/Sinter Operator

Inject. Mold, LS

2700 0.25 1 1 0.072 $1.65 $41.48 $151.77 $151.77 $0.12 $0.00 $0.06 $0.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.18 $0.18 $0.12

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 18 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Asm w/ Tape & Terminals Part Number: 180601-N0502-01d Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

23 H HV Medium Conn Asm BEC - Shield 180601-N0502-01d-47 1 Stamp T1 Assembly, Mark-up Applied 

@ Bottom.

S-Steel-304, Tube

Cut/Punch/Forming Operator Stamp/Form, SS 2400 0.25 1 1 0.090 $1.65 $42.73 $42.91 $42.91 $0.15 $0.00 $0.02 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.17 $0.15

24 H HV Medium Conn Asm BEC - Shield 180601-N0502-01d-48 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LMC 12000 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.00 $0.00 $0.00

25 H HV Medium Conn Asm BEC - Seal 180601-N0502-01d-49 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Thermoset-SBR Mold/Cast/Sinter Operator

Inject. Mold, LS

1867 0.25 1 1 0.004 $1.32 $41.48 $151.77 $151.77 $0.01 $0.01 $0.08 $0.09 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.09 $0.09 $0.01

26 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

27 H HV Large Conn Asm BEC - Body 180601-N0502-01d-50 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom.

Nylon6, Inject.

Mold/Cast/Sinter Operator

Inject. Mold, LS

2400 0.25 1 1 0.145 $1.65 $41.48 $151.77 $151.77 $0.24 $0.00 $0.06 $0.31 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.31 $0.31 $0.24

28 H HV Large Conn Asm BEC - Shield 180601-N0502-01d-51 1 Stamp T1 Assembly, Mark-up Applied 

@ Bottom.

S-Steel-304, Tube

Cut/Punch/Forming Operator Stamp/Form, SS 2400 0.25 1 1 0.017 $1.65 $42.73 $42.91 $42.91 $0.03 $0.00 $0.02 $0.05 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.05 $0.05 $0.03

29 H HV Large Conn Asm BEC - Shield 180601-N0502-01d-52 1 Wash T1 Assembly, Mark-up Applied 29 H HV Large Conn Asm BEC - Shield 180601-N0502-01d-52 1 Wash Not Applicable General Assembly Washing Equipment, LMC 15000 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.00 $0.00 $0.00 T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LMC 15000 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.00 $0.00 $0.00

30 H HV Large Conn Asm BEC - Seal 180601-N0502-01d-53 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Thermoset-SBR Mold/Cast/Sinter Operator

Inject. Mold, LS

2520 0.25 1 1 0.007 $1.32 $41.48 $151.77 $151.77 $0.01 $0.00 $0.06 $0.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.07 $0.07 $0.01

31 H HV Large Conn Asm BEC - Lock 180601-N0502-01d-54 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom.

Nylon6, Inject.

Mold/Cast/Sinter Operator

Inject. Mold, LS

1029 0.25 1 1 0.054 $1.65 $41.48 $151.77 $151.77 $0.09 $0.01 $0.15 $0.25 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.25 $0.25 $0.09

32 0

T1 Assembly, Mark-up Applied 

@ Bottom. ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0.00% #N/A #N/A $0.00 $0.00

33 H HV Cable Clamp Large Conn BEC - Base 180601-N0502-01d-55 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator

Inject. Mold, LS

3600 0.25 1 1 0.024 $1.74 $41.48 $151.77 $151.77 $0.04 $0.00 $0.04 $0.09 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.09 $0.09 $0.04

34 H HV Cable Clamp Large Conn BEC - Cover 180601-N0502-01d-56 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, LS 4320 0.25 1 1 0.015 $1.74 $41.48 $151.77 $151.77 $0.03 $0.00 $0.04 $0.06 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.06 $0.06 $0.03

35 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

36 H HV Large Conn Asm TCM - Body 180601-N0502-01d-57 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom.

Nylon6, Inject.

Mold/Cast/Sinter Operator

Inject. Mold, LS

2400 0.25 1 1 0.145 $1.65 $41.48 $151.77 $151.77 $0.24 $0.00 $0.06 $0.31 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.31 $0.31 $0.24

37 H HV Large Conn Asm TCM - Shield 180601-N0502-01d-58 1 Stamp T1 Assembly, Mark-up Applied 

@ Bottom.

S-Steel-304, Tube

Cut/Punch/Forming Operator Stamp/Form, SS 2400 0.25 1 1 0.017 $1.65 $42.73 $42.91 $42.91 $0.03 $0.00 $0.02 $0.05 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.05 $0.05 $0.03

38 H HV Large Conn Asm TCM - Shield 180601-N0502-01d-59 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LMC 15000 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.00 $0.00 $0.00

39 H HV Large Conn Asm TCM - Seal 180601-N0502-01d-60 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Thermoset-SBR Mold/Cast/Sinter Operator

Inject. Mold, LS

2520 0.25 1 1 0.007 $1.32 $41.48 $151.77 $151.77 $0.01 $0.00 $0.06 $0.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.07 $0.07 $0.01

40 H HV Large Conn Asm TCM - Lock 180601-N0502-01d-61 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom.

Nylon6, Inject.

Mold/Cast/Sinter Operator

Inject. Mold, LS

1029 0.25 1 1 0.054 $1.65 $41.48 $151.77 $151.77 $0.09 $0.01 $0.15 $0.25 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.25 $0.25 $0.09

41 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

42 H HV Cable Clamp Large Conn TCM - Base 180601-N0502-01d-62 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, LS 3600 0.25 1 1 0.024 $1.74 $41.48 $151.77 $151.77 $0.04 $0.00 $0.04 $0.09 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.09 $0.09 $0.04

43 H HV Cable Clamp Large Conn TCM - Cover 180601-N0502-01d-63 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, LS 4320 0.25 1 1 0.015 $1.74 $41.48 $151.77 $151.77 $0.03 $0.00 $0.04 $0.06 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.06 $0.06 $0.03

44 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

45 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 H HV Boot Mount Bolt 180601-N0502-01d-64 3 S $0.00 $0.05 $0.00 $0.14 $0.14

2 H Wrap Tie, HV Harness Mount 180601-N0502-01d-65 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 H HV TPA, Med Connector AC 180601-N0502-01d-66 2 S $0.00 $0.03 $0.00 $0.06 $0.06

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

6 H HV TPA, Med Connector DC-DC 180601-N0502-01d-67 2 S $0.00 $0.03 $0.00 $0.06 $0.06

7 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: 5 of 18 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Asm w/ Tape & Terminals Part Number: 180601-N0502-01d Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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 H HV TPA, Med Connector BEC 180601-N0502-01d-68 2 S $0.00 $0.03 $0.00 $0.06 $0.06

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 H HV TPA, Lrg Connector BEC 180601-N0502-01d-69 1 S $0.00 $0.03 $0.00 $0.03 $0.03

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 H HV TPA, Lrg Connector TCM 180601-N0502-01d-70 1 S $0.00 $0.03 $0.00 $0.03 $0.03

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

Supplier for Subassembly.

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$3.11

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

Mark-up $13.78

T1 or OEM Total Manufacturing Cost: $3.11 $6.56 $4.11 $13.78 $0.00 $0.00 $0.00 $0.00 $0.00 $13.78

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 ----- ----- ----- $0.07 $0.90 $0.83 $0.34 $2.14

Base Cost Impact to Vehicle: $3.11 $6.56 $4.11 $13.78 $0.07 $0.90 $0.83 $0.34 $2.14 $15.91 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $15.91

Total Number of Pallets/

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

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additional Information

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 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 Returnable 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

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 18 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Asm w/ Tape & Terminals Part Number: 180601-N0502-01d Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

Cost per Base: 6" Pallet Base, $100/Base Packaging Cost Total: $0.000

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: 7 of 18 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H HV Cable Boot 180601-N0502-01d-01

H HV Cable Boot Mount Asm 180601-N0502-01d-02

$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

$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

$0.24 $0.09 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 1 Sta w/ 1 Oper for SSLC, manually insert cables through boot 5 2 10 100 47 4700 96 37.60 85% 113 31.96 34 1 1 22 1.0 1.0

$0.26 $0.10 $0.36 $0.00 $0.00 $0.00 $0.00 $0.00 1 Sta w/ 1 Oper for SSLC, manually insert cables through boot mount up to boot 5 2 10 100 47 4700 96 37.60 85% 113 31.96 24 1 1 24 1.0 1.0

H HV Cable Boot Mount Asm - Wrap Tie 180601-N0502-01d-03

H HV Medium Conn Asm AC 180601-N0502-01d-04

H HV Medium Conn Asm AC - Seals 180601-N0502-01d-05

H HV Medium Conn Asm AC - Shields 180601-N0502-01d-06

H HV Medium Conn Asm AC - TPA & SC 180601-N0502-01d-07

$0.15 $0.06 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 1 Sta w/ 1 Opererator, wrap tie cable bundle through boot mount asm to mount base bracket, trim to length 

w/ hand tool 5 2 10 100 47 4700 96 37.60 85% 113 31.96 17 1 1 14 1.0 1.0

$0.24 $0.09 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Operator repositions harness & assemble harness end (slide over terminals) to connector body sub-ass'y 5 2 10 100 47 4700 96 37.60 85% 113 31.96 24 1 1 22 1.0 1.0

$0.24 $0.09 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Operator slide seals (2) into connector body 5 2 10 100 47 4700 96 37.60 85% 113 31.96 24 1 1 22 1.0 1.0

$0.15 $0.06 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 Operator push shields (2) into connector body 5 2 10 100 47 4700 96 37.60 85% 113 31.96 15 1 1 14 1.0 1.0

$0.28 $0.11 $0.39 $0.00 $0.00 $0.00 $0.00 $0.00 Operator Lock connector to harness (w/ 2x TPAs) connect small to med connector bodies 5 2 10 100 47 4700 96 37.60 85% 113 31.96 34 1 1 26 1.0 1.0

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 18 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

H HV Cable Clamp Curve Asm 180601-N0502-01d-08

H HV Medium Conn Asm DC-DC 180601-N0502-01d-09

H HV Medium Conn Asm DC-DC - Seals 180601-N0502-01d-10

H HV Medium Conn Asm DC-DC - Shields 180601-N0502-01d-11

H HV Medium Conn Asm DC-DC - TPA & SC 180601-N0502-01d-12

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

$0.26 $0.10 $0.36 $0.00 $0.00 $0.00 $0.00 $0.00 Operator snap halves together & reposition harness for next connector 5 2 10 100 47 4700 96 37.60 85% 113 31.96 32 1 1 24 1.0 1.0

$0.24 $0.09 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Operator repositions harness & assemble harness end (slide over terminals) to connector body sub-ass'y 5 2 10 100 47 4700 96 37.60 85% 113 31.96 24 1 1 22 1.0 1.0

$0.24 $0.09 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Operator slide seals (2) into connector body 5 2 10 100 47 4700 96 37.60 85% 113 31.96 24 1 1 22 1.0 1.0

$0.15 $0.06 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 Operator push shields (2) into connector body 5 2 10 100 47 4700 96 37.60 85% 113 31.96 15 1 1 14 1.0 1.0

$0.28 $0.11 $0.39 $0.00 $0.00 $0.00 $0.00 $0.00 Operator Lock connector to harness (w/ 2x TPAs) connect small to med connector bodies 5 2 10 100 47 4700 96 37.60 85% 113 31.96 34 1 1 26 1.0 1.0

H HV Cable Clamp Straight Asm 180601-N0502-01d-13

H HV Medium Conn Asm BEC 180601-N0502-01d-14

H HV Medium Conn Asm BEC - Seals 180601-N0502-01d-15

H HV Medium Conn Asm BEC - Shields 180601-N0502-01d-16

H HV Medium Conn Asm BEC - TPA & SC 180601-N0502-01d-17

H HV Medium Conn Asm BEC - Conn Caps 180601-N0502-01d-18

H HV Large Conn Asm BEC 180601-N0502-01d-19

H HV Large Conn Asm BEC - Seals 180601-N0502-01d-20

H HV Large Conn Asm BEC - Shields 180601-N0502-01d-21

H HV Large Conn Asm BEC - Lock 180601-N0502-01d-22

H HV Lrg Conn BEC Clamp Asm 180601-N0502-01d-23

H HV Large Conn Asm BEC - TPA 180601-N0502-01d-24

H HV Large Conn Asm TCM 180601-N0502-01d-25

$0.26 $0.10 $0.36 $0.00 $0.00 $0.00 $0.00 $0.00 Operator snap halves together & reposition harness for next connector 5 2 10 100 47 4700 96 37.60 85% 113 31.96 32 1 1 24 1.0 1.0

$0.24 $0.09 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Operator repositions harness & assemble harness end (slide over terminals) to connector body sub-ass'y 5 2 10 100 47 4700 96 37.60 85% 113 31.96 24 1 1 22 1.0 1.0

$0.24 $0.09 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Operator slide seals (2) into connector body 5 2 10 100 47 4700 96 37.60 85% 113 31.96 24 1 1 22 1.0 1.0

$0.15 $0.06 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 Operator push shields (2) into connector body 5 2 10 100 47 4700 96 37.60 85% 113 31.96 15 1 1 14 1.0 1.0

$0.28 $0.11 $0.39 $0.00 $0.00 $0.00 $0.00 $0.00 Operator Lock connector to harness (w/ 2x TPAs) connect small to med connector bodies 5 2 10 100 47 4700 96 37.60 85% 113 31.96 34 1 1 26 1.0 1.0

$0.26 $0.10 $0.36 $0.00 $0.00 $0.00 $0.00 $0.00 Operator slide forward Conn Caps (x2) to snap lock on ends of Med Conn and reposition harness asm 5 2 10 100 47 4700 96 37.60 85% 113 31.96 28 1 1 24 1.0 1.0

$0.27 $0.10 $0.37 $0.00 $0.00 $0.00 $0.00 $0.00 Operator assemble harness BEC end (slide over terminals) to connector body sub-ass'y 5 2 10 100 47 4700 96 37.60 85% 113 31.96 27 1 1 25 1.0 1.0

$0.24 $0.09 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Operator slide seals (2) into connector body 5 2 10 100 47 4700 96 37.60 85% 113 31.96 25 1 1 22 1.0 1.0

$0.15 $0.06 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 Operator push shields (2) into connector body 5 2 10 100 47 4700 96 37.60 85% 113 31.96 15 1 1 14 1.0 1.0

$0.04 $0.03 $0.08 $0.00 $0.00 $0.00 $0.00 $0.00 Operator snaps lock over connector body 5 2 10 100 47 4700 96 37.60 85% 113 31.96 8 1 1 8 1.0 1.0

$0.26 $0.10 $0.36 $0.00 $0.00 $0.00 $0.00 $0.00 Operator snap clamp halves together 5 2 10 100 47 4700 96 37.60 85% 113 31.96 29 1 1 24 1.0 1.0

$0.24 $0.09 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Operator Lock connector to harness (w/ TPA) & reposition harness for next connector 5 2 10 100 47 4700 96 37.60 85% 113 31.96 25 1 1 22 1.0 1.0

H HV Large Conn Asm TCM 180601-N0502-01d-25 $0.27 $0.10 $0.37 $0.00 $0.00 $0.00 $0.00 $0.00 Operator assemble harness BEC end (slide over terminals) to connector body sub-ass'y 5 2 10 100 47 4700 96 37.60 85% 113 31.96 27 1 1 25 1.0 1.0

H HV Large Conn Asm TCM - Seals 180601-N0502-01d-26

H HV Large Conn Asm TCM - Shields 180601-N0502-01d-27

H HV Large Conn Asm TCM - Lock 180601-N0502-01d-28

H HV Lrg Conn TCM Clamp Asm 180601-N0502-01d-29

H HV Large Conn Asm TCM - TPA 180601-N0502-01d-30

$0.27 $0.10 $0.37 $0.00 $0.00 $0.00 $0.00 $0.00 Operator assemble harness BEC end (slide over terminals) to connector body sub-ass'y 5 2 10 100 47 4700 96 37.60 85% 113 31.96 27 1 1 25 1.0 1.0

$0.24 $0.09 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Operator slide seals (2) into connector body 5 2 10 100 47 4700 96 37.60 85% 113 31.96 25 1 1 22 1.0 1.0

$0.15 $0.06 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 Operator push shields (2) into connector body 5 2 10 100 47 4700 96 37.60 85% 113 31.96 15 1 1 14 1.0 1.0

$0.04 $0.03 $0.08 $0.00 $0.00 $0.00 $0.00 $0.00 Operator snaps lock over connector body 5 2 10 100 47 4700 96 37.60 85% 113 31.96 8 1 1 8 1.0 1.0

$0.26 $0.10 $0.36 $0.00 $0.00 $0.00 $0.00 $0.00 Operator snap clamp halves together 5 2 10 100 47 4700 96 37.60 85% 113 31.96 29 1 1 24 1.0 1.0

$0.15 $0.06 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 Operator Lock connector to harness (w/ TPA) & reposition harness for next connector 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 14 1.0 1.0

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 18 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

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 $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

H HV Cable Boot 180601-N0502-01d-31

H HV Cable Boot Mount Asm - Body 180601-N0502-01d-32

H HV Cable Boot Mount Asm 180601-N0502-01d-33

H HV Medium Conn Asm AC - Body 180601-N0502-01d-34

H HV Medium Conn Asm AC - Shield 180601-N0502-01d-35

H HV Medium Conn Asm AC - Shield 180601-N0502-01d-36

H HV Medium Conn Asm AC - Seal 180601-N0502-01d-37

H HV Cable Clamp Curved - Base 180601-N0502-01d-38

H HV Cable Clamp Curved - Cover 180601-N0502-01d-39

H HV Medium Conn Asm DC-DC - Body 180601-N0502-01d-40

H HV Medium Conn Asm DC-DC - Shield 180601-N0502-01d-41

H HV Medium Conn Asm DC-DC - Shield 180601-N0502-01d-42

$0.00 $0.02 $0.79 $0.00 $0.00 $0.00 $0.00 $0.00 800-1500 Ton Injection Molding w/ 10 cavity mold for boot, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 7 1 10 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

$0.02 $0.16 $0.36 $0.00 $0.00 $0.00 $0.00 $0.00 200-400 Ton Injection Molding w/ 4 cavity mold for mounting plate w/ manual bolt insertion, operator cycle 

controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 15 1 4 15 1.0 1.0

$0.02 $0.04 $0.06 $0.00 $0.00 $0.00 $0.00 $0.00 2 position indexing table for lower mold half tooling to allow machine operator (above) to load bolts (x3ea) 

into each mold cavity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 12 1 4 12 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 $0.06 $0.18 $0.00 $0.00 $0.00 $0.00 $0.00 200-400 Ton Injection Molding w/ 12 cavity mold for med connector, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 1 12 16 1.0 1.0

$0.00 $0.02 $0.17 $0.00 $0.00 $0.00 $0.00 $0.00 25 Ton press - progressive, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 2 1 2 3 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 (Wash, Rinse & Dry), operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 17 1 50 15 1.0 1.0

$0.01 $0.08 $0.09 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 14 cavity mold, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 27 1 14 27 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 $0.04 $0.06 $0.00 $0.00 $0.00 $0.00 $0.00 200-400 Ton Injection Molding w/ 12 cavity mold for curved clamp base, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 1 12 11 1.0 1.0

$0.00 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00 $0.00 200-400 Ton Injection Molding w/ 12 cavity mold for curved clamp cover, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 1 12 11 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 $0.06 $0.18 $0.00 $0.00 $0.00 $0.00 $0.00 200-400 Ton Injection Molding w/ 12 cavity mold for med connector, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 1 12 16 1.0 1.0

$0.00 $0.02 $0.17 $0.00 $0.00 $0.00 $0.00 $0.00 25 Ton press - progressive, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 2 1 2 3 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 (Wash, Rinse & Dry), operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 17 1 50 15 1.0 1.0

H HV Medium Conn Asm DC-DC - Seal 180601-N0502-01d-43

H HV Cable Clamp Straight - Base 180601-N0502-01d-44

H HV Cable Clamp Straight - Cover 180601-N0502-01d-45

H HV Medium Conn Asm BEC - Body 180601-N0502-01d-46

$0.01 $0.08 $0.09 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 14 cavity mold, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 27 1 14 27 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 $0.04 $0.06 $0.00 $0.00 $0.00 $0.00 $0.00 200-400 Ton Injection Molding w/ 12 cavity mold for curved clamp base, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 1 12 11 1.0 1.0

$0.00 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00 $0.00 200-400 Ton Injection Molding w/ 12 cavity mold for curved clamp cover, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 1 12 11 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 $0.06 $0.18 $0.00 $0.00 $0.00 $0.00 $0.00 200-400 Ton Injection Molding w/ 12 cavity mold for med connector, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 1 12 16 1.0 1.0

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 10 of 18 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

H HV Medium Conn Asm BEC - Shield 180601-N0502-01d-47

H HV Medium Conn Asm BEC - Shield 180601-N0502-01d-48

H HV Medium Conn Asm BEC - Seal 180601-N0502-01d-49

H HV Large Conn Asm BEC - Body 180601-N0502-01d-50

H HV Large Conn Asm BEC - Shield 180601-N0502-01d-51

H HV Large Conn Asm BEC - Shield 180601-N0502-01d-52

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 $0.02 $0.17 $0.00 $0.00 $0.00 $0.00 $0.00 25 Ton press - progressive, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 2 1 2 3 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 (Wash, Rinse & Dry), operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 17 1 50 15 1.0 1.0

$0.01 $0.08 $0.09 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 14 cavity mold, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 27 1 14 27 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 $0.06 $0.31 $0.00 $0.00 $0.00 $0.00 $0.00 200-400 Ton Injection Molding w/ 14 cavity mold for med connector, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 21 1 14 21 1.0 1.0

$0.00 $0.02 $0.05 $0.00 $0.00 $0.00 $0.00 $0.00 25 Ton press - progressive, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1 1 2 3 1.0 1.0

H HV Large Conn Asm BEC - Shield 180601-N0502-01d-52 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 (Wash, Rinse & Dry), operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 50 12 1.0 1.0

H HV Large Conn Asm BEC - Seal 180601-N0502-01d-53

H HV Large Conn Asm BEC - Lock 180601-N0502-01d-54

H HV Cable Clamp Large Conn BEC - Base 180601-N0502-01d-55

H HV Cable Clamp Large Conn BEC - Cover 180601-N0502-01d-56

H HV Large Conn Asm TCM - Body 180601-N0502-01d-57

H HV Large Conn Asm TCM - Shield 180601-N0502-01d-58

H HV Large Conn Asm TCM - Shield 180601-N0502-01d-59

H HV Large Conn Asm TCM - Seal 180601-N0502-01d-60

H HV Large Conn Asm TCM - Lock 180601-N0502-01d-61

H HV Cable Clamp Large Conn TCM - Base 180601-N0502-01d-62

H HV Cable Clamp Large Conn TCM - Cover 180601-N0502-01d-63

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 (Wash, Rinse & Dry), operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 50 12 1.0 1.0

$0.00 $0.06 $0.07 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 14 cavity mold, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 20 1 14 20 1.0 1.0

$0.01 $0.15 $0.25 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 10 cavity mold for lrg conn lock, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 35 1 10 35 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 $0.04 $0.09 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 12 cavity mold for Lrg Conn BEC clamp base, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 12 1 12 12 1.0 1.0

$0.00 $0.04 $0.06 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 12 cavity mold for Lrg Conn BEC clamp cover, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 10 1 12 10 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 $0.06 $0.31 $0.00 $0.00 $0.00 $0.00 $0.00 200-400 Ton Injection Molding w/ 14 cavity mold for med connector, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 21 1 14 21 1.0 1.0

$0.00 $0.02 $0.05 $0.00 $0.00 $0.00 $0.00 $0.00 25 Ton press - progressive, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1 1 2 3 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 (Wash, Rinse & Dry), operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 50 12 1.0 1.0

$0.00 $0.06 $0.07 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 14 cavity mold, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 20 1 14 20 1.0 1.0

$0.01 $0.15 $0.25 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 10 cavity mold for lrg conn lock, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 35 1 10 35 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 $0.04 $0.09 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 12 cavity mold for Lrg Conn BEC clamp base, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 12 1 12 12 1.0 1.0

$0.00 $0.04 $0.06 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 12 cavity mold for Lrg Conn BEC clamp cover, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 10 1 12 10 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)

H HV Boot Mount Bolt 180601-N0502-01d-64

H Wrap Tie, HV Harness Mount 180601-N0502-01d-65

H HV TPA, Med Connector AC 180601-N0502-01d-66

H HV TPA, Med Connector DC-DC 180601-N0502-01d-67

$0.14

$0.01

$0.00

$0.06

$0.00

$0.06

$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: 11 of 18 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

H HV TPA, Med Connector BEC 180601-N0502-01d-68

H HV TPA, Lrg Connector BEC 180601-N0502-01d-69

H HV TPA, Lrg Connector TCM 180601-N0502-01d-70

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

$0.06

$0.00

$0.03

$0.00

$0.03

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$6.56 $4.11 $13.78 $0.00 $0.00 $0.00 $0.00 $0.00

$13.78

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: 12 of 18 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: 13 of 18 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H HV Cable Boot 180601-N0502-01d-01

H HV Cable Boot Mount Asm 180601-N0502-01d-02

#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! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

164 22.00 1.00

150 24.00 1.00

H HV Cable Boot Mount Asm - Wrap Tie 180601-N0502-01d-03

H HV Medium Conn Asm AC 180601-N0502-01d-04

H HV Medium Conn Asm AC - Seals 180601-N0502-01d-05

H HV Medium Conn Asm AC - Shields 180601-N0502-01d-06

H HV Medium Conn Asm AC - TPA & SC 180601-N0502-01d-07

257 14.00 1.00

164 22.00 1.00

164 22.00 1.00

257 14.00 1.00

138 26.00 1.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 14 of 18 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

H HV Cable Clamp Curve Asm 180601-N0502-01d-08

H HV Medium Conn Asm DC-DC 180601-N0502-01d-09

H HV Medium Conn Asm DC-DC - Seals 180601-N0502-01d-10

H HV Medium Conn Asm DC-DC - Shields 180601-N0502-01d-11

H HV Medium Conn Asm DC-DC - TPA & SC 180601-N0502-01d-12

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

150 24.00 1.00

164 22.00 1.00

164 22.00 1.00

257 14.00 1.00

138 26.00 1.00

H HV Cable Clamp Straight Asm 180601-N0502-01d-13

H HV Medium Conn Asm BEC 180601-N0502-01d-14

H HV Medium Conn Asm BEC - Seals 180601-N0502-01d-15

H HV Medium Conn Asm BEC - Shields 180601-N0502-01d-16

H HV Medium Conn Asm BEC - TPA & SC 180601-N0502-01d-17

H HV Medium Conn Asm BEC - Conn Caps 180601-N0502-01d-18

H HV Large Conn Asm BEC 180601-N0502-01d-19

H HV Large Conn Asm BEC - Seals 180601-N0502-01d-20

H HV Large Conn Asm BEC - Shields 180601-N0502-01d-21

H HV Large Conn Asm BEC - Lock 180601-N0502-01d-22

H HV Lrg Conn BEC Clamp Asm 180601-N0502-01d-23

H HV Large Conn Asm BEC - TPA 180601-N0502-01d-24

H HV Large Conn Asm TCM 180601-N0502-01d-25

150 24.00 1.00

164 22.00 1.00

164 22.00 1.00

257 14.00 1.00

138 26.00 1.00

150 24.00 1.00

144 25.00 1.00

164 22.00 1.00

257 14.00 1.00

450 8.00 0.50

150 24.00 1.00

164 22.00 1.00

H HV Large Conn Asm TCM 180601-N0502-01d-25 144 25.00 1.00

H HV Large Conn Asm TCM - Seals 180601-N0502-01d-26

H HV Large Conn Asm TCM - Shields 180601-N0502-01d-27

H HV Large Conn Asm TCM - Lock 180601-N0502-01d-28

H HV Lrg Conn TCM Clamp Asm 180601-N0502-01d-29

H HV Large Conn Asm TCM - TPA 180601-N0502-01d-30

144 25.00 1.00

164 22.00 1.00

257 14.00 1.00

450 8.00 0.50

150 24.00 1.00

257 14.00 1.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 15 of 18 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

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! -

H HV Cable Boot 180601-N0502-01d-31

H HV Cable Boot Mount Asm - Body 180601-N0502-01d-32

H HV Cable Boot Mount Asm 180601-N0502-01d-33

H HV Medium Conn Asm AC - Body 180601-N0502-01d-34

H HV Medium Conn Asm AC - Shield 180601-N0502-01d-35

H HV Medium Conn Asm AC - Shield 180601-N0502-01d-36

H HV Medium Conn Asm AC - Seal 180601-N0502-01d-37

H HV Cable Clamp Curved - Base 180601-N0502-01d-38

H HV Cable Clamp Curved - Cover 180601-N0502-01d-39

H HV Medium Conn Asm DC-DC - Body 180601-N0502-01d-40

H HV Medium Conn Asm DC-DC - Shield 180601-N0502-01d-41

H HV Medium Conn Asm DC-DC - Shield 180601-N0502-01d-42

5143 0.70 0.25

#DIV/0! #DIV/0! -

960 3.75 0.50

1200 3.00 0.50

#DIV/0! #DIV/0! -

2700 1.33 0.25

2400 1.50 0.25

12000 0.30 0.25

1867 1.93 0.25

#DIV/0! #DIV/0! -

3927 0.92 0.25

3927 0.92 0.25

#DIV/0! #DIV/0! -

2700 1.33 0.25

2400 1.50 0.25

12000 0.30 0.25

H HV Medium Conn Asm DC-DC - Seal 180601-N0502-01d-43

H HV Cable Clamp Straight - Base 180601-N0502-01d-44

H HV Cable Clamp Straight - Cover 180601-N0502-01d-45

H HV Medium Conn Asm BEC - Body 180601-N0502-01d-46

1867 1.93 0.25

#DIV/0! #DIV/0! -

3927 0.92 0.25

3927 0.92 0.25

#DIV/0! #DIV/0! -

2700 1.33 0.25

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 16 of 18 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

H HV Medium Conn Asm BEC - Shield 180601-N0502-01d-47

H HV Medium Conn Asm BEC - Shield 180601-N0502-01d-48

H HV Medium Conn Asm BEC - Seal 180601-N0502-01d-49

H HV Large Conn Asm BEC - Body 180601-N0502-01d-50

H HV Large Conn Asm BEC - Shield 180601-N0502-01d-51

H HV Large Conn Asm BEC - Shield 180601-N0502-01d-52

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

2400 1.50 0.25

12000 0.30 0.25

1867 1.93 0.25

#DIV/0! #DIV/0! -

2400 1.50 0.25

2400 1.50 0.25

H HV Large Conn Asm BEC - Shield 180601-N0502-01d-52 15000 0.24 0.25

H HV Large Conn Asm BEC - Seal 180601-N0502-01d-53

H HV Large Conn Asm BEC - Lock 180601-N0502-01d-54

H HV Cable Clamp Large Conn BEC - Base 180601-N0502-01d-55

H HV Cable Clamp Large Conn BEC - Cover 180601-N0502-01d-56

H HV Large Conn Asm TCM - Body 180601-N0502-01d-57

H HV Large Conn Asm TCM - Shield 180601-N0502-01d-58

H HV Large Conn Asm TCM - Shield 180601-N0502-01d-59

H HV Large Conn Asm TCM - Seal 180601-N0502-01d-60

H HV Large Conn Asm TCM - Lock 180601-N0502-01d-61

H HV Cable Clamp Large Conn TCM - Base 180601-N0502-01d-62

H HV Cable Clamp Large Conn TCM - Cover 180601-N0502-01d-63

15000 0.24 0.25

2520 1.43 0.25

1029 3.50 0.25

#DIV/0! #DIV/0! -

3600 1.00 0.25

4320 0.83 0.25

#DIV/0! #DIV/0! -

2400 1.50 0.25

2400 1.50 0.25

15000 0.24 0.25

2520 1.43 0.25

1029 3.50 0.25

#DIV/0! #DIV/0! -

3600 1.00 0.25

4320 0.83 0.25

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

H HV Boot Mount Bolt 180601-N0502-01d-64

H Wrap Tie, HV Harness Mount 180601-N0502-01d-65

H HV TPA, Med Connector AC 180601-N0502-01d-66

H HV TPA, Med Connector DC-DC 180601-N0502-01d-67

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 17 of 18 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

H HV TPA, Med Connector BEC 180601-N0502-01d-68

H HV TPA, Lrg Connector BEC 180601-N0502-01d-69

H HV TPA, Lrg Connector TCM 180601-N0502-01d-70

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: 18 of 18 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware Asm Part Number: 180601-N0502-01e Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

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

Power-Split HEV Technology

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-01 1

Assemble AC#1 Harn Asm to 

DC-DC#1 Harn Asm

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 240 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.16 $0.06 $0.22 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.22 $0.22 $0.00

2 H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-02 1

Assemble Trans Harn Asm to 

above Sub-Ass'y

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 200 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.19 $0.08 $0.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $0.27 $0.00

3 H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-03 1

Assemble BEC Harn Asm to T1 Assembly, Mark-up Applied 3 H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-03 1 Not Applicable General Assembly Elec. Assembly, LC, Base 180 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.21 $0.08 $0.30 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.30 $0.30 $0.00 Assemble BEC Harn Asm to 

above Sub-Ass'y

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 180 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.21 $0.08 $0.30 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.30 $0.30 $0.00

4 H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-04 1

Assemble Comm FB Harn Asm 

to above Sub-Ass'y

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 180 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.21 $0.08 $0.30 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.30 $0.30 $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

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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware Asm Part Number: 180601-N0502-01e Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-05 1 Inspect & tape on clips & label T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 200 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.19 $0.08 $0.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $0.27 $0.00

2 H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-06 1 Tape convltd tube lengths T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 200 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.19 $0.08 $0.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $0.27 $0.00

3 H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-07 1

Assemble convoluted tubing, 

foil/mesh tape

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 300 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.13 $0.05 $0.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.18 $0.18 $0.00

4 H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-08 1 Tape bundle routing lengths T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 225 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.17 $0.07 $0.24 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.24 $0.24 $0.00

5 H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-09 1 Apply heat shrink tubing & cool T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 240 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.16 $0.06 $0.22 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.22 $0.22 $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

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

22 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

23 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

24 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

25 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

26 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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware Asm Part Number: 180601-N0502-01e Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

27 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

28 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

29 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

30 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 13mm Adhesive Heat Shrink 180601-N0502-01e-10 0.375 S $0.00 $0.14 $0.00 $0.05 $0.05

2 3/8" Butyl Strip Caulk 180601-N0502-01e-11 0.417 S $0.00 $0.11 $0.00 $0.05 $0.05

3 25mm Orange Convolute 180601-N0502-01e-12 0.25 S $0.00 $0.15 $0.00 $0.04 $0.04

4 19mm Orange Convolute 180601-N0502-01e-13 2.917 S $0.00 $0.12 $0.00 $0.35 $0.35

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

4 19mm Orange Convolute 180601-N0502-01e-13 2.917 S "SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to $0.00 $0.12 $0.00 $0.35 $0.35

5 16mm Orange Convolute 180601-N0502-01e-14 4.25 S $0.00 $0.09 $0.00 $0.38 $0.38

6 Std Tape on Clips 180601-N0502-01e-15 3 S $0.00 $0.03 $0.00 $0.09 $0.09

7 Large Tape on Clip 180601-N0502-01e-16 1 S $0.00 $0.06 $0.00 $0.06 $0.06

8 Strap on Clips 180601-N0502-01e-17 2 S $0.00 $0.05 $0.00 $0.09 $0.09

9 Tape on Label 180601-N0502-01e-18 1 S $0.00 $0.10 $0.00 $0.10 $0.10

10 3/4" Orange Tape 180601-N0502-01e-19 122.3 S $0.00 $0.01 $0.00 $1.22 $1.22

11 3/4" Black Tape 180601-N0502-01e-20 1.417 S $0.00 $0.01 $0.00 $0.01 $0.01

12 3/4" Black Duct Tape 180601-N0502-01e-21 6.25 S $0.00 $0.02 $0.00 $0.09 $0.09

13 1" Black Fabric 180601-N0502-01e-22 1.038 S $0.00 $0.02 $0.00 $0.02 $0.02

14 80mm Wide Foil & Mesh Tape 180601-N0502-01e-23 1.5 S $0.00 $0.84 $0.00 $1.26 $1.26

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$3.81

"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.

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

Supplier for Subassembly.

$3.81

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

Mark-up $6.07

T1 or OEM Total Manufacturing Cost: $3.81 $1.63 $0.63 $6.07 $0.00 $0.00 $0.00 $0.00 $0.00 $6.07

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 $0.39 $0.36 $0.15 $0.94

Base Cost Impact to Vehicle: $3.81 $1.63 $0.63 $6.07 $0.03 $0.39 $0.36 $0.15 $0.94 $7.01 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $7.01

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: 4 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware Asm Part Number: 180601-N0502-01e Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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 Other #1 Other #1 Other #2 Other #2 Other #3 Other #3 

PACKAGING CALCULATIONS: 

Packaging Type: 

Part Size: 

Parts/Layer: 

Number of Layers: 

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable 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

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, 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: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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)

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-01

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-02

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-03

$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

$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

$0.16 $0.06 $0.22 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble AC#1 Harn Asm to DC-DC#1 Harn Asm by routing & bundling wires 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 15 1.0 1.0

$0.19 $0.08 $0.27 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble Trans Harn Asm to above Sub-Ass'y by routing & bundling wires 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 18 1.0 1.0

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-03 $0.21 $0.08 $0.30 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble BEC Harn Asm to above Sub-Ass'y by routing & bundling wires 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 20 1.0 1.0

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-04

$0.21 $0.08 $0.30 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble BEC Harn Asm to above Sub-Ass'y by routing & bundling wires 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 20 1.0 1.0

$0.21 $0.08 $0.30 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble Comm FB Harn Asm to above Sub-Ass'y by routing & bundling wires 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 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 $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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-05

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-06

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-07

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-08

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-09

$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

$0.19 $0.08 $0.27 $0.00 $0.00 $0.00 $0.00 $0.00 Oper visual inspection & tape connectors clips along length, coil & final packout 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 18 1.0 1.0

$0.19 $0.08 $0.27 $0.00 $0.00 $0.00 $0.00 $0.00 Oper wrap convoluted tubing lengths with tape, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 18 1.0 1.0

$0.13 $0.05 $0.18 $0.00 $0.00 $0.00 $0.00 $0.00 Oper snap on convoluted tubing lengths, apply foil mesh tape lengths, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 12 1.0 1.0

$0.17 $0.07 $0.24 $0.00 $0.00 $0.00 $0.00 $0.00 Route wire paths & bundle groups by spacing tape wraps, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 16 1.0 1.0

$0.16 $0.06 $0.22 $0.00 $0.00 $0.00 $0.00 $0.00 Operator apply heat shrink tubing w/ adhesive to wire length w/ heat gun, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 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

$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! #DIV/0! 85% 0 #DIV/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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

13mm Adhesive Heat Shrink 180601-N0502-01e-10

3/8" Butyl Strip Caulk 180601-N0502-01e-11

25mm Orange Convolute 180601-N0502-01e-12

19mm Orange Convolute 180601-N0502-01e-13

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

$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

$0.05

$0.04

19mm Orange Convolute 180601-N0502-01e-13 $0.35

16mm Orange Convolute 180601-N0502-01e-14

Std Tape on Clips 180601-N0502-01e-15

Large Tape on Clip 180601-N0502-01e-16

Strap on Clips 180601-N0502-01e-17

Tape on Label 180601-N0502-01e-18

3/4" Orange Tape 180601-N0502-01e-19

3/4" Black Tape 180601-N0502-01e-20

3/4" Black Duct Tape 180601-N0502-01e-21

1" Black Fabric 180601-N0502-01e-22

80mm Wide Foil & Mesh Tape 180601-N0502-01e-23

$0.35

$0.38

$0.09

$0.06

$0.09

$0.10

$1.22

$0.01

$0.09

$0.02

$1.26

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$1.63 $0.63 $6.07 $0.00 $0.00 $0.00 $0.00 $0.00

$6.07

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: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-01

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-02

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-03

#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! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

240 15.00 1.00

200 18.00 1.00

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-03 180 20.00 1.00

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-04

180 20.00 1.00

180 20.00 1.00

#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: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-05

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-06

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-07

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-08

H HV Harn Misc Commodity Hardware Asm 180601-N0502-01e-09

#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! -

200 18.00 1.00

200 18.00 1.00

300 12.00 1.00

225 16.00 1.00

240 15.00 1.00

#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! -

#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: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

13mm Adhesive Heat Shrink 180601-N0502-01e-10

3/8" Butyl Strip Caulk 180601-N0502-01e-11

25mm Orange Convolute 180601-N0502-01e-12

19mm Orange Convolute 180601-N0502-01e-13

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! -

19mm Orange Convolute 180601-N0502-01e-13

16mm Orange Convolute 180601-N0502-01e-14

Std Tape on Clips 180601-N0502-01e-15

Large Tape on Clip 180601-N0502-01e-16

Strap on Clips 180601-N0502-01e-17

Tape on Label 180601-N0502-01e-18

3/4" Orange Tape 180601-N0502-01e-19

3/4" Black Tape 180601-N0502-01e-20

3/4" Black Duct Tape 180601-N0502-01e-21

1" Black Fabric 180601-N0502-01e-22

80mm Wide Foil & Mesh Tape 180601-N0502-01e-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: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - AC #1 Part Number: 180601-N0502-01f Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-01 1 Inspect & Final Ass'y T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 225 2 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.34 $0.07 $0.41 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.41 $0.41 $0.00

2 H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-02 1 Electrical Test T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 240 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.16 $0.06 $0.22 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.22 $0.22 $0.00

3 H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-03 1 Tape Ass'y T1 Assembly, Mark-up Applied 3 H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-03 1 Tape Ass'y Not Applicable General Assembly Elec. Assembly, LC, Base 257 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $0.00 T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 257 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $0.00

4 H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-04 1 Routing & Bundling T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 327 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.24 $0.09 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

5 H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-05 1 Crimping T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 600 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.03 $0.03 $0.06 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.06 $0.06 $0.00

6 H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-06 1 Asm Seals, Caps & Keepers T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 200 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.19 $0.08 $0.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $0.27 $0.00

7 H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-07 1 Cut Length & End Prep T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 450 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.09 $0.03 $0.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.12 $0.12 $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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - AC #1 Part Number: 180601-N0502-01f Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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

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

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - AC #1 Part Number: 180601-N0502-01f Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

29 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

30 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 2.72mm Shielded Cable 180601-N0502-01f-08 4.667 S $0.00 $2.39 $0.00 $11.18 $11.18

2 JB Seal Keepers (Red) 180601-N0502-01f-09 2 S $0.00 $0.04 $0.00 $0.08 $0.08

3 JB Conn Seals (Drk Green) 180601-N0502-01f-10 2 S $0.00 $0.11 $0.00 $0.21 $0.21

4 2.8mm Female Terminals 180601-N0502-01f-11 4 S $0.00 $0.03 $0.00 $0.10 $0.10

5 Conn Seals (Blue) 180601-N0502-01f-12 2 S $0.00 $0.11 $0.00 $0.22 $0.22

6 Med Grnd Caps & Ferrules 180601-N0502-01f-13 4 S $0.00 $0.02 $0.00 $0.07 $0.07

"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 6 Med Grnd Caps & Ferrules 180601-N0502-01f-13 4 S $0.00 $0.02 $0.00 $0.07 $0.07

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 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$11.86

Material Labor Burden TMC Scrap SG&A Profit ED&T Total $13.47

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

Mark-up Calculations.

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

Supplier for Subassembly.

Material Labor Burden TMC Scrap SG&A Profit ED&T 1

Mark-up $13.47

T1 or OEM Total Manufacturing Cost: $11.86 $1.20 $0.41 $13.47 $0.00 $0.00 $0.00 $0.00 $0.00 $13.47

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 ----- ----- ----- $0.07 $0.88 $0.81 $0.34 $2.09

Base Cost Impact to Vehicle: $11.86 $1.20 $0.41 $13.47 $0.07 $0.88 $0.81 $0.34 $2.09 $15.56 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $15.56

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - AC #1 Part Number: 180601-N0502-01f Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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 

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

PACKAGING CALCULATIONS: 

Packaging Type: 

Part Size: 

Parts/Layer: 

Number of Layers: 

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable 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.

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

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: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-01

H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-02

H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-03

$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

$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

$0.34 $0.07 $0.41 $0.00 $0.00 $0.00 $0.00 $0.00 Operator visual inspection, coil & final packout 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 16 1.0 1.0

$0.16 $0.06 $0.22 $0.00 $0.00 $0.00 $0.00 $0.00 Test sta w/ operator load/connect & disconnect/unload, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 15 1.0 1.0

H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-03 $0.15 $0.06 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 Operator tape lengths, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 14 1.0 1.0

H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-04

H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-05

H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-06

H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-07

$0.15 $0.06 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 Operator tape lengths, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 14 1.0 1.0

$0.24 $0.09 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Route wire paths & bundle groups, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 22 1.0 2.0

$0.03 $0.03 $0.06 $0.00 $0.00 $0.00 $0.00 $0.00 Crimp caps & ferrules and terminals, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 6 1.0 1.0

$0.19 $0.08 $0.27 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble seals, caps and keepers, operator load/unload, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 18 1.0 1.0

$0.09 $0.03 $0.12 $0.00 $0.00 $0.00 $0.00 $0.00 Wire length cut & end strip sta, operator load/unload, feed from wire spools, packout to totes for next 

station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

$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

$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! #DIV/0! 85% 0 #DIV/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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

2.72mm Shielded Cable 180601-N0502-01f-08

JB Seal Keepers (Red) 180601-N0502-01f-09

JB Conn Seals (Drk Green) 180601-N0502-01f-10

2.8mm Female Terminals 180601-N0502-01f-11

Conn Seals (Blue) 180601-N0502-01f-12

Med Grnd Caps & Ferrules 180601-N0502-01f-13

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 $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

$11.18

$0.08

$0.21

$0.10

$0.22

Med Grnd Caps & Ferrules 180601-N0502-01f-13 $0.07

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$1.20 $0.41 $13.47 $0.00 $0.00 $0.00 $0.00 $0.00

$13.47

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: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-01

H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-02

H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-03

#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! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

225 16.00 2.00

240 15.00 1.00

H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-03 257 14.00 1.00

H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-04

H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-05

H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-06

H HV Harn Misc Commodity Hardware - AC #1 180601-N0502-01f-07

257 14.00 1.00

327 11.00 2.00

600 6.00 0.50

200 18.00 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: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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

#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! -

#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! -

#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: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

2.72mm Shielded Cable 180601-N0502-01f-08

JB Seal Keepers (Red) 180601-N0502-01f-09

JB Conn Seals (Drk Green) 180601-N0502-01f-10

2.8mm Female Terminals 180601-N0502-01f-11

Conn Seals (Blue) 180601-N0502-01f-12

Med Grnd Caps & Ferrules 180601-N0502-01f-13

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Med Grnd Caps & Ferrules 180601-N0502-01f-13

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - DC-DC #1 Part Number: 180601-N0502-01g Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

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

Power-Split HEV Technology

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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

H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--01 1 Inspect & Final Ass'y T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 225 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.17 $0.07 $0.24 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.24 $0.24 $0.00

2

H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--02 1 Electrical Test T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 240 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.16 $0.06 $0.22 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.22 $0.22 $0.00

3

H HV Harn Misc Commodity Hardware - DC-DC 180601-N0502-01g--03 1 Tape Ass'y T1 Assembly, Mark-up Applied 3 Not Applicable General Assembly Elec. Assembly, LC, Base 257 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $0.00 H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--03 1 Tape Ass'y T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 257 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $0.00

4

H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--04 1 Routing & Bundling T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 300 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.26 $0.10 $0.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.36 $0.36 $0.00

5

H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--05 1 Crimping T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 600 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.03 $0.03 $0.06 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.06 $0.06 $0.00

6

H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--06 1 Asm Seals, Caps & Keepers T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 200 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.19 $0.08 $0.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $0.27 $0.00

7

H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--07 1 Cut Length & End Prep T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 450 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.09 $0.03 $0.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.12 $0.12 $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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - DC-DC #1 Part Number: 180601-N0502-01g Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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

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

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - DC-DC #1 Part Number: 180601-N0502-01g Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

29 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

30 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 2.72mm Shielded Cable 180601-N0502-01g--08 8.5 S $0.00 $2.39 $0.00 $20.36 $20.36

2 JB Seal Keepers (Red) 180601-N0502-01g--09 2 S $0.00 $0.04 $0.00 $0.08 $0.08

3 JB Conn Seals (Drk Green) 180601-N0502-01g--10 2 S $0.00 $0.11 $0.00 $0.21 $0.21

4 2.8mm Female Terminals 180601-N0502-01g--11 4 S $0.00 $0.03 $0.00 $0.10 $0.10

5 Conn Seals (Blue) 180601-N0502-01g--12 2 S $0.00 $0.11 $0.00 $0.22 $0.22

6 Med Grnd Caps & Ferrules 180601-N0502-01g--13 4 S $0.00 $0.02 $0.00 $0.07 $0.07

"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 6 Med Grnd Caps & Ferrules 180601-N0502-01g--13 4 S $0.00 $0.02 $0.00 $0.07 $0.07

7 0 S $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 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$21.04

Material Labor Burden TMC Scrap SG&A Profit ED&T Total $22.51

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

Mark-up Calculations.

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

Supplier for Subassembly.

Material Labor Burden TMC Scrap SG&A Profit ED&T 1

Mark-up $22.51

T1 or OEM Total Manufacturing Cost: $21.04 $1.05 $0.42 $22.51 $0.00 $0.00 $0.00 $0.00 $0.00 $22.51

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 ----- ----- ----- $0.11 $1.46 $1.35 $0.56 $3.49

Base Cost Impact to Vehicle: $21.04 $1.05 $0.42 $22.51 $0.11 $1.46 $1.35 $0.56 $3.49 $25.99 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $25.99

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - DC-DC #1 Part Number: 180601-N0502-01g Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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 

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

PACKAGING CALCULATIONS: 

Packaging Type: 

Part Size: 

Parts/Layer: 

Number of Layers: 

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable 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.

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

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: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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)

H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--01

H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--02

H HV Harn Misc Commodity Hardware - DC-DC 180601-N0502-01g--03

$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

$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

$0.17 $0.07 $0.24 $0.00 $0.00 $0.00 $0.00 $0.00 Operator visual inspection, coil & final packout 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 16 1.0 1.0

$0.16 $0.06 $0.22 $0.00 $0.00 $0.00 $0.00 $0.00 Test sta w/ operator load/connect & disconnect/unload, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 15 1.0 1.0

$0.15 $0.06 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 Operator tape lengths, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 14 1.0 1.0 H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--03

H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--04

H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--05

H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--06

H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--07

$0.15 $0.06 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 Operator tape lengths, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 14 1.0 1.0

$0.26 $0.10 $0.36 $0.00 $0.00 $0.00 $0.00 $0.00 Route wire paths & bundle groups, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 24 1.0 2.0

$0.03 $0.03 $0.06 $0.00 $0.00 $0.00 $0.00 $0.00 Crimp caps & ferrules and terminals, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 6 1.0 1.0

$0.19 $0.08 $0.27 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble seals, caps and keepers, operator load/unload, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 18 1.0 1.0

$0.09 $0.03 $0.12 $0.00 $0.00 $0.00 $0.00 $0.00 Wire length cut & end strip sta, operator load/unload, feed from wire spools, packout to totes for next 

station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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

$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

$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! #DIV/0! 85% 0 #DIV/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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

2.72mm Shielded Cable 180601-N0502-01g--08

JB Seal Keepers (Red) 180601-N0502-01g--09

JB Conn Seals (Drk Green) 180601-N0502-01g--10

2.8mm Female Terminals 180601-N0502-01g--11

Conn Seals (Blue) 180601-N0502-01g--12

Med Grnd Caps & Ferrules 180601-N0502-01g--13

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

$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

$20.36

$0.08

$0.21

$0.10

$0.22

Med Grnd Caps & Ferrules 180601-N0502-01g--13 $0.07

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$1.05 $0.42 $22.51 $0.00 $0.00 $0.00 $0.00 $0.00

$22.51

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: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--01

H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--02

H HV Harn Misc Commodity Hardware - DC-DC 180601-N0502-01g--03

#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! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

225 16.00 1.00

240 15.00 1.00

257 14.00 1.00 H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--03

H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--04

H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--05

H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--06

H HV Harn Misc Commodity Hardware - DC-DC 

#1 180601-N0502-01g--07

257 14.00 1.00

300 12.00 2.00

600 6.00 0.50

200 18.00 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: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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

#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! -

#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! -

#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: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

2.72mm Shielded Cable 180601-N0502-01g--08

JB Seal Keepers (Red) 180601-N0502-01g--09

JB Conn Seals (Drk Green) 180601-N0502-01g--10

2.8mm Female Terminals 180601-N0502-01g--11

Conn Seals (Blue) 180601-N0502-01g--12

Med Grnd Caps & Ferrules 180601-N0502-01g--13

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Med Grnd Caps & Ferrules 180601-N0502-01g--13

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - Trans Part Number: 180601-N0502-01h Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-01 1 Inspect & Final Ass'y T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 225 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.17 $0.07 $0.24 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.24 $0.24 $0.00

2 H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-02 1 Electrical Test T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 240 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.16 $0.06 $0.22 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.22 $0.22 $0.00

3 H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-03 1 Tape Ass'y T1 Assembly, Mark-up Applied 3 H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-03 1 Tape Ass'y Not Applicable General Assembly Elec. Assembly, LC, Base 257 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $0.00 T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 257 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $0.00

4 H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-04 1 Routing & Bundling T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 277 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.28 $0.11 $0.39 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.39 $0.39 $0.00

5 H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-05 1 Crimping T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 600 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.03 $0.03 $0.06 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.06 $0.06 $0.00

6 H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-06 1 Assemble Seals T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 450 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.09 $0.03 $0.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.12 $0.12 $0.00

7 H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-07 1 Cut Length & End Prep T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 450 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.09 $0.03 $0.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.12 $0.12 $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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - Trans Part Number: 180601-N0502-01h Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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

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

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - Trans Part Number: 180601-N0502-01h Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

29 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

30 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 5.49mm Shielded Cable 180601-N0502-01h-08 25.33 S $0.00 $2.13 $0.00 $54.05 $54.05

2 Conn Seals, Large (Lt Green) 180601-N0502-01h-09 4 S $0.00 $0.10 $0.00 $0.38 $0.38

3 Lrg Grnd Caps & Ferrules 180601-N0502-01h-10 4 S $0.00 $0.02 $0.00 $0.10 $0.10

4 5.5mm Female Terminals 180601-N0502-01h-11 4 S $0.00 $0.10 $0.00 $0.40 $0.40

5 Terminal Align Guides 180601-N0502-01h-12 4 S $0.00 $0.03 $0.00 $0.12 $0.12

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 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 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$55.05

Material Labor Burden TMC Scrap SG&A Profit ED&T Total $56.40

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

Mark-up Calculations.

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

Supplier for Subassembly.

Material Labor Burden TMC Scrap SG&A Profit ED&T 1

Mark-up $56.40

T1 or OEM Total Manufacturing Cost: $55.05 $0.96 $0.39 $56.40 $0.00 $0.00 $0.00 $0.00 $0.00 $56.40

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 ----- ----- ----- $0.28 $3.67 $3.38 $1.41 $8.74

Base Cost Impact to Vehicle: $55.05 $0.96 $0.39 $56.40 $0.28 $3.67 $3.38 $1.41 $8.74 $65.14 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $65.14

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - Trans Part Number: 180601-N0502-01h Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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 

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

PACKAGING CALCULATIONS: 

Packaging Type: 

Part Size: 

Parts/Layer: 

Number of Layers: 

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable 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.

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

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: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-01

H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-02

H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-03

$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

$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

$0.17 $0.07 $0.24 $0.00 $0.00 $0.00 $0.00 $0.00 Operator visual inspection, coil & final packout 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 16 1.0 1.0

$0.16 $0.06 $0.22 $0.00 $0.00 $0.00 $0.00 $0.00 Test sta w/ operator load/connect & disconnect/unload, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 15 1.0 1.0

H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-03 $0.15 $0.06 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 Operator tape lengths, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 14 1.0 1.0

H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-04

H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-05

H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-06

H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-07

$0.15 $0.06 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 Operator tape lengths, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 14 1.0 1.0

$0.28 $0.11 $0.39 $0.00 $0.00 $0.00 $0.00 $0.00 Route wire paths & bundle groups, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 26 1.0 2.0

$0.03 $0.03 $0.06 $0.00 $0.00 $0.00 $0.00 $0.00 Crimp caps & ferrules and terminals, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 6 1.0 1.0

$0.09 $0.03 $0.12 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble seals, operator load/unload, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 8 1.0 1.0

$0.09 $0.03 $0.12 $0.00 $0.00 $0.00 $0.00 $0.00 Wire length cut & end strip sta, operator load/unload, feed from wire spools, packout to totes for next 

station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

$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

$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! #DIV/0! 85% 0 #DIV/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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

5.49mm Shielded Cable 180601-N0502-01h-08

Conn Seals, Large (Lt Green) 180601-N0502-01h-09

Lrg Grnd Caps & Ferrules 180601-N0502-01h-10

5.5mm Female Terminals 180601-N0502-01h-11

Terminal Align Guides 180601-N0502-01h-12

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 $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

$54.05

$0.38

$0.10

$0.40

$0.12

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$0.96 $0.39 $56.40 $0.00 $0.00 $0.00 $0.00 $0.00

$56.40

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: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-01

H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-02

H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-03

#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! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

225 16.00 1.00

240 15.00 1.00

H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-03 257 14.00 1.00

H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-04

H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-05

H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-06

H HV Harn Misc Commodity Hardware - Trans 180601-N0502-01h-07

257 14.00 1.00

277 13.00 2.00

600 6.00 0.50

450 8.00 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: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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

#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! -

#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! -

#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: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

5.49mm Shielded Cable 180601-N0502-01h-08

Conn Seals, Large (Lt Green) 180601-N0502-01h-09

Lrg Grnd Caps & Ferrules 180601-N0502-01h-10

5.5mm Female Terminals 180601-N0502-01h-11

Terminal Align Guides 180601-N0502-01h-12

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#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: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - BEC Part Number: 180601-N0502-01i Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

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

Power-Split HEV Technology

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-01 1 Inspect & Final Ass'y T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 225 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.17 $0.07 $0.24 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.24 $0.24 $0.00

2 H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-02 1 Electrical Test T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 240 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.16 $0.06 $0.22 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.22 $0.22 $0.00

3 H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-03 1 Tape Ass'y T1 Assembly, Mark-up Applied 3 H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-03 1 Tape Ass'y Not Applicable General Assembly Elec. Assembly, LC, Base 257 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $0.00 T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 257 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $0.00

4 H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-04 1 Routing & Bundling T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 277 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.28 $0.11 $0.39 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.39 $0.39 $0.00

5 H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-05 1 Crimping T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 600 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.03 $0.03 $0.06 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.06 $0.06 $0.00

6 H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-06 1 Asm Seals, Caps & Keepers T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 200 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.19 $0.08 $0.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $0.27 $0.00

7 H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-07 1 Cut Length & End Prep T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 450 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.09 $0.03 $0.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.12 $0.12 $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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - BEC Part Number: 180601-N0502-01i Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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

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

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - BEC Part Number: 180601-N0502-01i Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

29 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

30 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 2.72mm Shielded Cable 180601-N0502-01i-08 25.67 S $0.00 $0.76 $0.00 $19.56 $19.56

2 Conn Caps (Orange) 180601-N0502-01i-09 2 S $0.00 $0.20 $0.00 $0.40 $0.40

3 Conn Seals (Blue) 180601-N0502-01i-10 2 S $0.00 $0.11 $0.00 $0.22 $0.22

4 Med Grnd Caps & Ferrules 180601-N0502-01i-11 4 S $0.00 $0.02 $0.00 $0.07 $0.07

5 JB Seal Keepers (Red) 180601-N0502-01i-12 2 S $0.00 $0.04 $0.00 $0.08 $0.08

6 JB Conn Seals (Drk Green) 180601-N0502-01i-13 2 S $0.00 $0.11 $0.00 $0.21 $0.21

"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 6 JB Conn Seals (Drk Green) 180601-N0502-01i-13 2 S $0.00 $0.11 $0.00 $0.21 $0.21

7 2.8mm Female Terminals 180601-N0502-01i-14 4 S $0.00 $0.03 $0.00 $0.10 $0.10

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

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$20.64

Material Labor Burden TMC Scrap SG&A Profit ED&T Total $22.14

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

Mark-up Calculations.

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

Supplier for Subassembly.

Material Labor Burden TMC Scrap SG&A Profit ED&T 1

Mark-up $22.14

T1 or OEM Total Manufacturing Cost: $20.64 $1.07 $0.43 $22.14 $0.00 $0.00 $0.00 $0.00 $0.00 $22.14

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 ----- ----- ----- $0.11 $1.44 $1.33 $0.55 $3.43

Base Cost Impact to Vehicle: $20.64 $1.07 $0.43 $22.14 $0.11 $1.44 $1.33 $0.55 $3.43 $25.57 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $25.57

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - BEC Part Number: 180601-N0502-01i Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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 

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

PACKAGING CALCULATIONS: 

Packaging Type: 

Part Size: 

Parts/Layer: 

Number of Layers: 

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable 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.

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

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: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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)

H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-01

H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-02

H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-03

$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

$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

$0.17 $0.07 $0.24 $0.00 $0.00 $0.00 $0.00 $0.00 Operator visual inspection, coil & final packout 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 16 1.0 1.0

$0.16 $0.06 $0.22 $0.00 $0.00 $0.00 $0.00 $0.00 Test sta w/ operator load/connect & disconnect/unload, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 15 1.0 1.0

H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-03 $0.15 $0.06 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 Operator tape lengths, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 14 1.0 1.0

H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-04

H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-05

H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-06

H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-07

$0.15 $0.06 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 Operator tape lengths, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 14 1.0 1.0

$0.28 $0.11 $0.39 $0.00 $0.00 $0.00 $0.00 $0.00 Route wire paths & bundle groups, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 26 1.0 2.0

$0.03 $0.03 $0.06 $0.00 $0.00 $0.00 $0.00 $0.00 Crimp caps & ferrules and terminals, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 6 1.0 1.0

$0.19 $0.08 $0.27 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble seals, caps and keepers, operator load/unload, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 18 1.0 1.0

$0.09 $0.03 $0.12 $0.00 $0.00 $0.00 $0.00 $0.00 Wire length cut & end strip sta, operator load/unload, feed from wire spools, packout to totes for next 

station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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

$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

$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! #DIV/0! 85% 0 #DIV/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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

2.72mm Shielded Cable 180601-N0502-01i-08

Conn Caps (Orange) 180601-N0502-01i-09

Conn Seals (Blue) 180601-N0502-01i-10

Med Grnd Caps & Ferrules 180601-N0502-01i-11

JB Seal Keepers (Red) 180601-N0502-01i-12

JB Conn Seals (Drk Green) 180601-N0502-01i-13

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

$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

$19.56

$0.40

$0.22

$0.07

$0.08

JB Conn Seals (Drk Green) 180601-N0502-01i-13 $0.21

2.8mm Female Terminals 180601-N0502-01i-14 $0.10

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$1.07 $0.43 $22.14 $0.00 $0.00 $0.00 $0.00 $0.00

$22.14

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: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-01

H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-02

H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-03

#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! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

225 16.00 1.00

240 15.00 1.00

H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-03 257 14.00 1.00

H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-04

H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-05

H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-06

H HV Harn Misc Commodity Hardware - BEC 180601-N0502-01i-07

257 14.00 1.00

277 13.00 2.00

600 6.00 0.50

200 18.00 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: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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

#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! -

#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! -

#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: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

2.72mm Shielded Cable 180601-N0502-01i-08

Conn Caps (Orange) 180601-N0502-01i-09

Conn Seals (Blue) 180601-N0502-01i-10

Med Grnd Caps & Ferrules 180601-N0502-01i-11

JB Seal Keepers (Red) 180601-N0502-01i-12

JB Conn Seals (Drk Green) 180601-N0502-01i-13

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

JB Conn Seals (Drk Green) 180601-N0502-01i-13

2.8mm Female Terminals 180601-N0502-01i-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: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - Comm FB Part Number: 180601-N0502-1j Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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

H HV Harn Misc Commodity Hardware - Comm 

FB 180601-N0502-01j-01 1 Inspect & Final Ass'y T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 200 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.19 $0.08 $0.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $0.27 $0.00

2

H HV Harn Misc Commodity Hardware - Comm 

FB 180601-N0502-01j-02 1 Electrical Test T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 240 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.16 $0.06 $0.22 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.22 $0.22 $0.00

3

H HV Harn Misc Commodity Hardware - Comm 180601-N0502-01j-03 1 Routing & Terminal Insertion T1 Assembly, Mark-up Applied 3 Not Applicable General Assembly Elec. Assembly, LC, Base 327 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.24 $0.09 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00 H HV Harn Misc Commodity Hardware - Comm 

FB 180601-N0502-01j-03 1 Routing & Terminal Insertion T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 327 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.24 $0.09 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.33 $0.00

4

H HV Harn Misc Commodity Hardware - Comm 

FB 180601-N0502-01j-04 1 Crimping T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 514 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.04 $0.03 $0.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.07 $0.07 $0.00

5

H HV Harn Misc Commodity Hardware - Comm 

FB 180601-N0502-01j-05 1 Cut Length & End Prep T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 400 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.10 $0.04 $0.13 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.13 $0.13 $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

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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - Comm FB Part Number: 180601-N0502-1j Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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

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

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - Comm FB Part Number: 180601-N0502-1j Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

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 18 gauge Wire 180601-N0502-01j-06 60.83 S $0.00 $0.02 $0.00 $1.22 $1.22

2 2 Cavity 1.5mm Seal Conn 180601-N0502-01j-07 3 S $0.00 $0.10 $0.00 $0.29 $0.29

3 1.5mm Female Spade Terms & Seals 180601-N0502-01j-08 6 S $0.00 $0.03 $0.00 $0.17 $0.17

4 1.0mm Male Spade Terms & Seals 180601-N0502-01j-09 4 S $0.00 $0.04 $0.00 $0.15 $0.15

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 $0.00

8 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.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 8 0 $0.00 $0.00 $0.00 $0.00 $0.00

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$1.83

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

Mark-up $2.85

T1 or OEM Total Manufacturing Cost: $1.83 $0.72 $0.30 $2.85 $0.00 $0.00 $0.00 $0.00 $0.00 $2.85

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

Supplier for Subassembly.

3

1

Notes: T1 or OEM Total Manufacturing Cost: $1.83 $0.72 $0.30 $2.85 $0.00 $0.00 $0.00 $0.00 $0.00 $2.85

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 $0.18 $0.17 $0.07 $0.44

Base Cost Impact to Vehicle: $1.83 $0.72 $0.30 $2.85 $0.01 $0.18 $0.17 $0.07 $0.44 $3.29 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $3.29

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 HV Harn Misc Commodity Hardware - Comm FB Part Number: 180601-N0502-1j Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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 

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 CALCULATIONS: 

Packaging Type: 

Part Size: 

Parts/Layer: 

Number of Layers: 

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable 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 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

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: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H HV Harn Misc Commodity Hardware - Comm 

FB 180601-N0502-01j-01

H HV Harn Misc Commodity Hardware - Comm 

FB 180601-N0502-01j-02

H HV Harn Misc Commodity Hardware - Comm 180601-N0502-01j-03

$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

$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

$0.19 $0.08 $0.27 $0.00 $0.00 $0.00 $0.00 $0.00 Operator visual inspection and coil & final packout 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 18 1.0 1.0

$0.16 $0.06 $0.22 $0.00 $0.00 $0.00 $0.00 $0.00 Test sta w/ operator load/connect & disconnect/unload, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 15 1.0 1.0

$0.24 $0.09 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Route wire paths and insert terminals into connectors, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 22 1.0 2.0 H HV Harn Misc Commodity Hardware - Comm 

FB 180601-N0502-01j-03

H HV Harn Misc Commodity Hardware - Comm 

FB 180601-N0502-01j-04

H HV Harn Misc Commodity Hardware - Comm 

FB 180601-N0502-01j-05

$0.24 $0.09 $0.33 $0.00 $0.00 $0.00 $0.00 $0.00 Route wire paths and insert terminals into connectors, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 22 1.0 2.0

$0.04 $0.03 $0.07 $0.00 $0.00 $0.00 $0.00 $0.00 Crimp terminals on wires, packout to totes for next station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 7 1.0 1.0

$0.10 $0.04 $0.13 $0.00 $0.00 $0.00 $0.00 $0.00 Wire length cut & end strip sta, operator load/unload, feed from wire spools, packout to totes for next 

station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 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

$0.00 $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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

$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

$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! #DIV/0! 85% 0 #DIV/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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

18 gauge Wire 180601-N0502-01j-06

2 Cavity 1.5mm Seal Conn 180601-N0502-01j-07

1.5mm Female Spade Terms & Seals 180601-N0502-01j-08

1.0mm Male Spade Terms & Seals 180601-N0502-01j-09

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

$1.22

$0.29

$0.17

$0.15

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$0.72 $0.30 $2.85 $0.00 $0.00 $0.00 $0.00 $0.00

$2.85

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: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H HV Harn Misc Commodity Hardware - Comm 

FB 180601-N0502-01j-01

H HV Harn Misc Commodity Hardware - Comm 

FB 180601-N0502-01j-02

H HV Harn Misc Commodity Hardware - Comm 180601-N0502-01j-03

#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! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

200 18.00 1.00

240 15.00 1.00

327 11.00 2.00 H HV Harn Misc Commodity Hardware - Comm 

FB 180601-N0502-01j-03

H HV Harn Misc Commodity Hardware - Comm 

FB 180601-N0502-01j-04

H HV Harn Misc Commodity Hardware - Comm 

FB 180601-N0502-01j-05

327 11.00 2.00

514 7.00 0.50

400 9.00 1.00

#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: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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

#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! -

#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! -

#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: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

18 gauge Wire 180601-N0502-01j-06

2 Cavity 1.5mm Seal Conn 180601-N0502-01j-07

1.5mm Female Spade Terms & Seals 180601-N0502-01j-08

1.0mm Male Spade Terms & Seals 180601-N0502-01j-09

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: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Low 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 Bracket Asm, HV Cable to Trans Part Number: 180675-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

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

Power-Split HEV Technology

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 H Bracket Asm, HV Cable to Trans 180675-N0502-01-01 1 Snap together bracket clip T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 360 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.05 $0.04 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $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 H Bracket Asm, HV Cable to Trans 180675-N0502-01-02 1 Powder coat T1 Assembly, Mark-up Applied 

@ Bottom. Powder Coat General Assembly Powder Coat, LC 200 1 1 1 0.000 $20.00 $38.55 $100.00 $100.00 $0.00 $0.19 $0.50 $0.69 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.69 $0.69 $0.00

4 H Bracket Asm, HV Cable to Trans 180675-N0502-01-03 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LMC 2880 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.01 $0.01 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.01 $0.01 $0.00

5 H Bracket Asm, HV Cable to Trans 180675-N0502-01-04 1 Weld Nut T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Welding/Soldering Operator Mech Assembly, LC, Base 450 0.5 1 1 0.000 $0.00 $41.55 $15.00 $15.00 $0.00 $0.05 $0.03 $0.08 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.08 $0.08 $0.00

6 H Bracket Asm, HV Cable to Trans 180675-N0502-01-05 1 Engrave T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 200 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.19 $0.08 $0.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $0.27 $0.00

7 H Bracket Asm, HV Cable to Trans 180675-N0502-01-06 1 Stamp T1 Assembly, Mark-up Applied 

@ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS 1440 0.25 1 1 1.942 $0.45 $42.73 $42.91 $42.91 $0.87 $0.01 $0.03 $0.91 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.91 $0.91 $0.87

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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Low 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 Bracket Asm, HV Cable to Trans Part Number: 180675-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 H Bracket Clip, Trans 180675-N0502-01-07 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 2571 0.25 1 1 0.000 $1.74 $41.48 $28.80 $28.80 $0.00 $0.00 $0.01 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.02 $0.02 $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 1.942 #N/A #N/A #N/A #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 0.030 #N/A #N/A #N/A #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

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Low 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 Bracket Asm, HV Cable to Trans Part Number: 180675-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

29 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

30 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 H Weld Nut - 6mm Sqr 180675-N0502-01-08 1 S $0.00 $0.02 $0.00 $0.02 $0.02

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

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.

"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 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 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.89

Material Labor Burden TMC Scrap SG&A Profit ED&T Total $2.09

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

Mark-up Calculations.

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

Supplier for Subassembly.

Material Labor Burden TMC Scrap SG&A Profit ED&T 1

Mark-up $2.09

T1 or OEM Total Manufacturing Cost: $0.89 $0.50 $0.70 $2.09 $0.00 $0.00 $0.00 $0.00 $0.00 $2.09

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 1.00% 11.30%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.13 $0.08 $0.02 $0.24

Base Cost Impact to Vehicle: $0.89 $0.50 $0.70 $2.09 $0.01 $0.13 $0.08 $0.02 $0.24 $2.33 $0 $0

Packaging Cost: $0.05

Net Cost Impact to Vehicle: $2.37

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Low 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 Bracket Asm, HV Cable to Trans Part Number: 180675-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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 

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

PACKAGING CALCULATIONS: 

Packaging Type: 

Part Size: 

Parts/Layer: 

Number of Layers: 

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable 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.

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

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: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

Takt 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

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)

H Bracket Asm, HV Cable to Trans 180675-N0502-01-01

H Bracket Asm, HV Cable to Trans 180675-N0502-01-02

$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

$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 $0.04 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 1 Sta w/ 1 Oper for SSLC attach clip to bracket 5 2 10 100 47 4700 96 37.60 85% 113 31.96 10 1 1 10 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

$0.19 $0.50 $0.69 $0.00 $0.00 $0.00 $0.00 $0.00 Powder Coat Line (Inlcudes prep, coat and cure), Conveyor line, operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 1 1 18 1.0 1.0

H Bracket Asm, HV Cable to Trans 180675-N0502-01-03

H Bracket Asm, HV Cable to Trans 180675-N0502-01-04

H Bracket Asm, HV Cable to Trans 180675-N0502-01-05

H Bracket Asm, HV Cable to Trans 180675-N0502-01-06

$0.00 $0.01 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, oper load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 8 10 1.0 1.0

$0.05 $0.03 $0.08 $0.00 $0.00 $0.00 $0.00 $0.00 Weld nut on back of bracket w/ single weld head, manual part load, operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 17 1 1 8 1.0 1.0

$0.19 $0.08 $0.27 $0.00 $0.00 $0.00 $0.00 $0.00 Simple station engraver, operator load/unload fixture 5 2 10 100 47 4700 96 37.60 85% 113 31.96 19 1 1 18 1.0 1.0

$0.01 $0.03 $0.91 $0.00 $0.00 $0.00 $0.00 $0.00 200-400 Ton Stamping Press, operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 2 1 2 5 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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

Takt 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

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

H Bracket Clip, Trans 180675-N0502-01-07

$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 $0.01 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 Simple 10 cavity mold w/ auto-eject pins, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 14 1 10 14 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! #DIV/0! 85% 0 #DIV/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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

H Weld Nut - 6mm Sqr 180675-N0502-01-08

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

Takt 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

$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

$0.02

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$0.50 $0.70 $2.09 $0.00 $0.00 $0.00 $0.00 $0.00

$2.09

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: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

Takt 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: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H Bracket Asm, HV Cable to Trans 180675-N0502-01-01

H Bracket Asm, HV Cable to Trans 180675-N0502-01-02

#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! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

360 10.00 0.50

#DIV/0! #DIV/0! -

200 18.00 1.00

H Bracket Asm, HV Cable to Trans 180675-N0502-01-03

H Bracket Asm, HV Cable to Trans 180675-N0502-01-04

H Bracket Asm, HV Cable to Trans 180675-N0502-01-05

H Bracket Asm, HV Cable to Trans 180675-N0502-01-06

2880 1.25 0.25

450 8.00 0.50

200 18.00 1.00

1440 2.50 0.25

#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: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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

H Bracket Clip, Trans 180675-N0502-01-07

#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! -

2571 1.40 0.25

#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! -

#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: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

H Weld Nut - 6mm Sqr 180675-N0502-01-08

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#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: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Low 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 Bracket Asm, HV Cable to Dash Part Number: 180675-N0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 H Bracket Asm, HV Cable to Dash 180675-N0502-02-01 1 Push together bushing asm T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 257 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $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 H Bracket Asm, HV Cable to Dash 180675-N0502-02-02 1 Powder coat T1 Assembly, Mark-up Applied 

@ Bottom. Powder Coat General Assembly Powder Coat, LC 240 1 1 1 0.000 $20.00 $38.55 $100.00 $100.00 $0.00 $0.16 $0.42 $0.58 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.58 $0.58 $0.00

4 H Bracket Asm, HV Cable to Dash 180675-N0502-02-03 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LMC 3600 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.01 $0.01 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.01 $0.01 $0.00

5 H Bracket Asm, HV Cable to Dash 180675-N0502-02-04 1 Spot Weld Brace T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Welding/Soldering Operator Mech Assembly, LC, Base 400 1 1 1 0.000 $0.00 $41.55 $15.00 $15.00 $0.00 $0.10 $0.04 $0.14 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.14 $0.14 $0.00

6 H Bracket Asm, HV Cable to Dash 180675-N0502-02-05 1 Stamp T1 Assembly, Mark-up Applied 

@ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS 1800 0.25 1 1 0.397 $0.45 $42.73 $42.91 $42.91 $0.18 $0.01 $0.02 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21 $0.18

7 0

T1 Assembly, Mark-up Applied 

@ Bottom. ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0.00% #N/A #N/A $0.00 $0.00

8 H Bracket Stiffener, Dash Bracket 180675-N0502-02-06 1 Engrave T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 200 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.19 $0.08 $0.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $0.27 $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: 2 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Low 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 Bracket Asm, HV Cable to Dash Part Number: 180675-N0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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 H Bracket Stiffener, Dash Bracket 180675-N0502-02-07 1 Stamp T1 Assembly, Mark-up Applied 

@ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS 2400 0.25 1 1 0.357 $0.45 $42.73 $42.91 $42.91 $0.16 $0.00 $0.02 $0.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.18 $0.18 $0.16

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 H Bushing Asm, Dash Bracket 180675-N0502-02-08 3 Push insert into bushing T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 600 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.03 $0.03 $0.06 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.06 $0.17 $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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 H Bushing Asm, Dash Bracket 180675-N0502-02-02-09 3 Mold T1 Assembly, Mark-up Applied 

@ Bottom. Thermoset-NR Mold/Cast/Sinter Operator Inject. Mold, SS 3600 0.25 1 1 0.014 $2.14 $41.48 $16.39 $16.39 $0.03 $0.00 $0.00 $0.04 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.04 $0.11 $0.09

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 H Anti-Crush Insert, Bushing Asm 180675-N0502-02-02-10 1 Paint T1 Assembly, Mark-up Applied 

@ Bottom. Powder Coat General Assembly Powder Coat, LC 9000 0.25 1 1 0.000 $20.00 $38.55 $100.00 $100.00 $0.00 $0.00 $0.01 $0.01 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.01 $0.01 $0.00

4 H Anti-Crush Insert, Bushing Asm 180675-N0502-02-02-11 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LMC 7200 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.00 $0.00 $0.00

5 H Anti-Crush Insert, Bushing Asm 180675-N0502-02-02-12 3 Stamp T1 Assembly, Mark-up Applied 

@ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS 3600 0.25 1 1 0.014 $0.45 $42.73 $42.91 $42.91 $0.01 $0.00 $0.01 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.02 $0.06 $0.02

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

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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Low 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 Bracket Asm, HV Cable to Dash Part Number: 180675-N0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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, 

Cost Unit PIA 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

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 $0.00

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

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 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.

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

Supplier for Subassembly.

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.45

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

Mark-up $1.96

T1 or OEM Total Manufacturing Cost: $0.45 $0.74 $0.77 $1.96 $0.00 $0.00 $0.00 $0.00 $0.00 $1.96

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 1.00% 11.30%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.12 $0.08 $0.02 $0.22

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: 4 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Low 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 Bracket Asm, HV Cable to Dash Part Number: 180675-N0502-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

Base Cost Impact to Vehicle: $0.45 $0.74 $0.77 $1.96 $0.01 $0.12 $0.08 $0.02 $0.22 $2.18 $0 $0

Packaging Cost: $0.03

Net Cost Impact to Vehicle: $2.20

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 Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable Last 5 Years

Piece (%)

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/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

Number of Layers: 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: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H Bracket Asm, HV Cable to Dash 180675-N0502-02-01

H Bracket Asm, HV Cable to Dash 180675-N0502-02-02

$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

$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

$0.15 $0.06 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 1 Sta w/ 1 Oper for SSLC, fixture - manually attach bushing asm (x3) to bracket 5 2 10 100 47 4700 96 37.60 85% 113 31.96 25 1 1 14 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

$0.16 $0.42 $0.58 $0.00 $0.00 $0.00 $0.00 $0.00 Powder Coat Line (Inlcudes prep, coat and cure), Conveyor line, operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 1 1 15 1.0 1.0

H Bracket Asm, HV Cable to Dash 180675-N0502-02-03

H Bracket Asm, HV Cable to Dash 180675-N0502-02-04

H Bracket Asm, HV Cable to Dash 180675-N0502-02-05

H Bracket Stiffener, Dash Bracket 180675-N0502-02-06

$0.00 $0.01 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo tunnel washer w/ conveyor, oper load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 10 10 1.0 1.0

$0.10 $0.04 $0.14 $0.00 $0.00 $0.00 $0.00 $0.00 Spot weld brace on back of bracket (4 places) w/ single weld head, manual part load, operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 17 1 1 9 1.0 1.0

$0.01 $0.02 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 200 Ton Progressive Stamping Press, operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 2 1 2 4 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

$0.19 $0.08 $0.27 $0.00 $0.00 $0.00 $0.00 $0.00 Simple station engraver, operator load/unload fixture 5 2 10 100 47 4700 96 37.60 85% 113 31.96 18 1 1 18 1.0 1.0

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

H Bracket Stiffener, Dash Bracket 180675-N0502-02-07

H Bushing Asm, Dash Bracket 180675-N0502-02-08

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 $0.02 $0.18 $0.00 $0.00 $0.00 $0.00 $0.00 25 Ton Stamping Press, operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 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

$0.10 $0.08 $0.17 $0.00 $0.00 $0.00 $0.00 $0.00 1 Sta w/ 1 Oper for SSLC push insert into bushing (x3) 5 2 10 100 47 4700 287 12.53 85% 338 10.65 8 1 1 6 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 - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

H Bushing Asm, Dash Bracket 180675-N0502-02-02-09

H Anti-Crush Insert, Bushing Asm 180675-N0502-02-02-10

H Anti-Crush Insert, Bushing Asm 180675-N0502-02-02-11

H Anti-Crush Insert, Bushing Asm 180675-N0502-02-02-12

$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

$0.01 $0.01 $0.11 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 10 cavity mold for bushing body, operator cycle controls 5 2 10 100 47 4700 287 12.53 85% 338 10.65 10 1 10 10 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 $0.01 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 Powder Coat Line (Inlcudes prep, coat and cure), Conveyor line, operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 9 1 20 8 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 (wash, rinse & dry), operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 20 10 1.0 1.0

$0.01 $0.04 $0.06 $0.00 $0.00 $0.00 $0.00 $0.00 0-60 Ton Stamping Press, operator load/unload 5 2 10 100 47 4700 287 12.53 85% 338 10.65 1 1 2 2 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! #DIV/0! 85% 0 #DIV/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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

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 $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

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$0.74 $0.77 $1.96 $0.00 $0.00 $0.00 $0.00 $0.00

$1.96

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: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H Bracket Asm, HV Cable to Dash 180675-N0502-02-01

H Bracket Asm, HV Cable to Dash 180675-N0502-02-02

#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! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

257 14.00 1.00

#DIV/0! #DIV/0! -

240 15.00 1.00

H Bracket Asm, HV Cable to Dash 180675-N0502-02-03

H Bracket Asm, HV Cable to Dash 180675-N0502-02-04

H Bracket Asm, HV Cable to Dash 180675-N0502-02-05

H Bracket Stiffener, Dash Bracket 180675-N0502-02-06

3600 1.00 0.25

400 9.00 1.00

1800 2.00 0.25

#DIV/0! #DIV/0! -

200 18.00 1.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

H Bracket Stiffener, Dash Bracket 180675-N0502-02-07

H Bushing Asm, Dash Bracket 180675-N0502-02-08

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

2400 1.50 0.25

#DIV/0! #DIV/0! -

600 6.00 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! -

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

H Bushing Asm, Dash Bracket 180675-N0502-02-02-09

H Anti-Crush Insert, Bushing Asm 180675-N0502-02-02-10

H Anti-Crush Insert, Bushing Asm 180675-N0502-02-02-11

H Anti-Crush Insert, Bushing Asm 180675-N0502-02-02-12

#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! -

3600 1.00 0.25

#DIV/0! #DIV/0! -

9000 0.40 0.25

7200 0.50 0.25

3600 1.00 0.25

#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! -

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

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! -

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Low 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 Cover Cable Pass Thru Part Number: 180603-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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 2 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 2 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 2 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

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

Power-Split HEV Technology

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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

H Traction & HV Power Harness - Cover Cable 

Pass-Thru 180600-N0502-01-10 1 Mold T1 Assembly, Mark-up Applied @ Bottom. Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, LS 1350 0.25 1 1 0.192 $1.54 $41.48 $151.77 $151.77 $0.30 $0.01 $0.11 $0.42 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.42 $0.42 $0.30

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

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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Low 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 Cover Cable Pass Thru Part Number: 180603-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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

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

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Low 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 Cover Cable Pass Thru Part Number: 180603-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

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

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 $0.00

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

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 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.

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

Supplier for Subassembly.

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.30

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

Mark-up $0.42

T1 or OEM Total Manufacturing Cost: $0.30 $0.01 $0.11 $0.42 $0.00 $0.00 $0.00 $0.00 $0.00 $0.42

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 1.00% 11.30%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.02 $0.02 $0.00 $0.05

Base Cost Impact to Vehicle: $0.30 $0.01 $0.11 $0.42 $0.00 $0.02 $0.02 $0.00 $0.05 $0.46 $0 $0

Packaging Cost: $0.01

3

1

Notes: 

a) Items 1,2, & 3 must a

Packaging Cost: $0.01

Net Cost Impact to Vehicle: $0.47

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Low 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 Cover Cable Pass Thru Part Number: 180603-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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 

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 CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable 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 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

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: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 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 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 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

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)

H Traction & HV Power Harness - Cover Cable 

Pass-Thru 180600-N0502-01-10

$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

$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

$0.01 $0.11 $0.42 $0.00 $0.00 $0.00 $0.00 $0.00 400-800 Ton Injection Molding w/ 6 cavity mold for cable pass-thru cover, operator cycle controls 

(used PBT-GF30 Mat'l instead of PBT-GF33) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 1 6 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! #DIV/0! 85% 0 #DIV/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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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

$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

$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)

$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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$0.01 $0.11 $0.42 $0.00 $0.00 $0.00 $0.00 $0.00

$0.42

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: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H Traction & HV Power Harness - Cover Cable 

Pass-Thru 180600-N0502-01-10

#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! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

1350 2.67 0.25

#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: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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

#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! -

#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)

#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: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Battery Service Disconnect Asm Part Number: 180611-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 H Battery Service Disconnect Asm 180699-N0502-01-01 1

Insert terminals (2x) into base 

and place fuse

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 200 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.19 $0.08 $0.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $0.27 $0.00

2 H Battery Service Disconnect Asm 180699-N0502-01-02 1

Place washers (2x) & screws 

(2x) and torque

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 189 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.20 $0.08 $0.28 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.28 $0.28 $0.00

3 H Battery Service Disconnect Asm 180699-N0502-01-03 1 Install cover, latch & label T1 Assembly, Mark-up Applied 3 H Battery Service Disconnect Asm 180699-N0502-01-03 1 Install cover, latch & label Not Applicable General Assembly Elec. Assembly, LC, Base 180 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.21 $0.08 $0.30 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.30 $0.30 $0.00 T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 180 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.21 $0.08 $0.30 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.30 $0.30 $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

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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Battery Service Disconnect Asm Part Number: 180611-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 H Battery Service Base - Sub Asm 180699-N0502-01-04 1 Press insert nuts (2x) into base T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 171 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.22 $0.09 $0.31 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.31 $0.31 $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 H Battery Service Disconnect - Base 180699-N0502-01-05 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. PBT-GF20, Inject. Mold/Cast/Sinter Operator

Inject. Mold, SS

2769 0.25 1 1 0.116 $1.46 $41.48 $16.39 $16.39 $0.17 $0.00 $0.01 $0.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.18 $0.18 $0.17

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 H Battery Service Disconnect - Terminal 180699-N0502-01-06 1 Stamp T1 Assembly, Mark-up Applied 

@ Bottom. Copper-Pure, Wire Cut/Punch/Forming Operator Stamp/Form, SS 3600 0.25 1 1 0.114 $2.45 $42.73 $42.91 $42.91 $0.28 $0.00 $0.01 $0.29 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.29 $0.29 $0.28

11 H Battery Service Disconnect - Terminal 180699-N0502-01-07 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LMC 12000 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.00 $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 H Battery Service Disconnect - Cover 180699-N0502-01-08 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom. HD Polypro Mold/Cast/Sinter Operator

Inject. Mold, SS

2400 0.25 1 1 0.026 $0.87 $41.48 $16.39 $16.39 $0.02 $0.00 $0.01 $0.03 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.03 $0.03 $0.02

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 H Battery Service Disconnect - Latch 180699-N0502-01-09 1 Mold T1 Assembly, Mark-up Applied 

@ Bottom.

Nylon66-30GF, Inject.

Mold/Cast/Sinter Operator

Inject. Mold, SS

439 0.5 1 1 0.061 $1.54 $41.48 $16.39 $16.39 $0.09 $0.05 $0.04 $0.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.18 $0.18 $0.09

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

22 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

23 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

24 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

25 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

26 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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Battery Service Disconnect Asm Part Number: 180611-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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)

27 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

28 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

29 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

30 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 Fuse - 100A 180699-N0502-01-10 1 S $0.00 $1.25 $0.00 $1.25 $1.25

2 Washer 180699-N0502-01-11 2 S $0.00 $0.02 $0.00 $0.03 $0.03

3 Screw 180699-N0502-01-12 2 S $0.00 $0.06 $0.00 $0.12 $0.12

4 Label 180699-N0502-01-13 1 S $0.00 $0.10 $0.00 $0.10 $0.10

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

4 Label 180699-N0502-01-13 1 S "SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to $0.00 $0.10 $0.00 $0.10 $0.10

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

6 Insert Stud 180699-N0502-01-14 2 S $0.00 $0.04 $0.00 $0.08 $0.08

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 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$2.15

"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.

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

Supplier for Subassembly.

$2.15

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

Mark-up $3.43

T1 or OEM Total Manufacturing Cost: $2.15 $0.89 $0.39 $3.43 $0.00 $0.00 $0.00 $0.00 $0.00 $3.43

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 ----- ----- ----- $0.02 $0.22 $0.21 $0.09 $0.53

Base Cost Impact to Vehicle: $2.15 $0.89 $0.39 $3.43 $0.02 $0.22 $0.21 $0.09 $0.53 $3.96 $0 $0

Packaging Cost: $0.03

Net Cost Impact to Vehicle: $3.99

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: 4 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Battery Service Disconnect Asm Part Number: 180611-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

Power-Split HEV Technology

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 Other #1 Other #1 Other #2 Other #2 Other #3 Other #3 

PACKAGING CALCULATIONS: 

Packaging Type: 

Part Size: 

Parts/Layer: 

Number of Layers: 

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable 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

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, 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: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H Battery Service Disconnect Asm 180699-N0502-01-01

H Battery Service Disconnect Asm 180699-N0502-01-02

H Battery Service Disconnect Asm 180699-N0502-01-03

$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

$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

$0.19 $0.08 $0.27 $0.00 $0.00 $0.00 $0.00 $0.00 Operator installs terminals (2x) into battery service plug base, Push to depth in base, Place fuse over 

screw terminal bases. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 21 1 1 18 1.0 1.0

$0.20 $0.08 $0.28 $0.00 $0.00 $0.00 $0.00 $0.00 Operator installs washers (2x) & screws (2x) into battery service plug base, torque to spec w/ 2 spindle 

power assist tool 5 2 10 100 47 4700 96 37.60 85% 113 31.96 26 1 1 19 1.0 1.0

$0.21 $0.08 $0.30 $0.00 $0.00 $0.00 $0.00 $0.00 Operator install base cover and snaps into place, install latch around base body and snap into place, apply H Battery Service Disconnect Asm 180699-N0502-01-03 $0.21 $0.08 $0.30 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 96 37.60 85% 113 31.96 22 1 1 20 1.0 1.0 Operator install base cover and snaps into place, install latch around base body and snap into place, apply 

label on top of cover surface 5 2 10 100 47 4700 96 37.60 85% 113 31.96 22 1 1 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 $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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

H Battery Service Base - Sub Asm 180699-N0502-01-04

H Battery Service Disconnect - Base 180699-N0502-01-05

H Battery Service Disconnect - Terminal 180699-N0502-01-06

H Battery Service Disconnect - Terminal 180699-N0502-01-07

H Battery Service Disconnect - Cover 180699-N0502-01-08

H Battery Service Disconnect - Latch 180699-N0502-01-09

$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

$0.22 $0.09 $0.31 $0.00 $0.00 $0.00 $0.00 $0.00 Operator loads base to fixture & insert nuts (2x) to press head tool, cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 27 1 1 21 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 $0.01 $0.18 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 10 cavity mold for BS Plug Base, operator cycle controls 

(used PBT-GF20 Mat'l instead of PBT-GF30) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 10 13 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 $0.01 $0.29 $0.00 $0.00 $0.00 $0.00 $0.00 25 Ton press - progressive, operator cycle controls 

(used Copper-Pure, Wire instead of Copper-Pure, plate or strip configuration) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1 1 2 2 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 (Wash, Rinse & Dry), operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 50 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 $0.01 $0.03 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 10 cavity mold for BS Plug Base Cover, operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 15 1 10 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

$0.05 $0.04 $0.18 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Injection Molding w/ 10 cavity mold for BS Plug Latch, operator cycle controls 

(used Nylon66-30GF, Inject. Mat'l instead of Nylon66-14GF) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 82 1 10 82 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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

Fuse - 100A 180699-N0502-01-10

Washer 180699-N0502-01-11

Screw 180699-N0502-01-12

Label 180699-N0502-01-13

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 $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

$1.25

$0.03

$0.12

Label 180699-N0502-01-13 $0.10

Insert Stud 180699-N0502-01-14

$0.00

$0.08

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$0.89 $0.39 $3.43 $0.00 $0.00 $0.00 $0.00 $0.00

$3.43

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: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

H Battery Service Disconnect Asm 180699-N0502-01-01

H Battery Service Disconnect Asm 180699-N0502-01-02

H Battery Service Disconnect Asm 180699-N0502-01-03

#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! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

200 18.00 1.00

189 19.00 1.00

H Battery Service Disconnect Asm 180699-N0502-01-03 180 20.00 1.00

#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: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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

H Battery Service Base - Sub Asm 180699-N0502-01-04

H Battery Service Disconnect - Base 180699-N0502-01-05

H Battery Service Disconnect - Terminal 180699-N0502-01-06

H Battery Service Disconnect - Terminal 180699-N0502-01-07

H Battery Service Disconnect - Cover 180699-N0502-01-08

H Battery Service Disconnect - Latch 180699-N0502-01-09

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

171 21.00 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

2769 1.30 0.25

#DIV/0! #DIV/0! -

3600 1.00 0.25

12000 0.30 0.25

#DIV/0! #DIV/0! -

2400 1.50 0.25

#DIV/0! #DIV/0! -

439 8.20 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! -

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

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

Fuse - 100A 180699-N0502-01-10

Washer 180699-N0502-01-11

Screw 180699-N0502-01-12

Label 180699-N0502-01-13

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! -

Label 180699-N0502-01-13

Insert Stud 180699-N0502-01-14

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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#: B0502 (B = Base, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: Part Number: Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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

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 HEV Technology 

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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

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

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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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#: B0502 (B = Base, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: Part Number: Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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 HEV Technology 

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)

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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

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

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

22 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

23 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

24 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

25 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

26 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

27 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

28 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

29 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

30 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 "S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubFile: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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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#: B0502 (B = Base, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: Part Number: Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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 HEV Technology 

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)

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

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 $0.00

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

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 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.

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

Supplier for Subassembly.

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.00

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

Mark-up $0.00

T1 or OEM Total Manufacturing Cost: $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- #N/A #N/A #N/A #N/A #N/A

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- #N/A #N/A #N/A #N/A #N/A

Base Cost Impact to Vehicle: $0.00 $0.00 $0.00 $0.00 #N/A #N/A #N/A #N/A #N/A #N/A $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: #N/A

3

1

Notes: 

a) Items 1,2, & 3 must a

Net Cost Impact to Vehicle: #N/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)

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable 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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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#: B0502 (B = Base, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: Part Number: Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life: Production Year: 2009/2010

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 HEV Technology 

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)

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: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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)

$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

$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! #DIV/0! 85% 0 #DIV/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

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 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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

$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

$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)

$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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

$0.00

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: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

#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! -

#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! -

#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: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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

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

#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! -

#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)

#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: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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
Assembly Report

H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$83.31 Tool H Traction & HV First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Power 

Distribution Sub

- - - Bracket Trans Axle Mounted - - - - - -

$35.51 Subassembly H Traction & HV H Bracket Asm, HV Cable to H Bracket Asm, 8.0000 sec 8.0000 sec - $0.19 1

Power Trans HV Cable to 

Distribution Sub Trans

$35.51 Tool H Bracket Asm, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

HV Cable to 

Trans

$35.51 Subassembly H Bracket Asm, H Bracket, HV Cable to Trans, H Bracket, HV 3.0000 sec 3.0000 sec - $0.03 1

HV Cable to Painted Cable to Trans, 

Trans Painted

$35.51 Tool H Bracket, HV First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cable to Trans, 

Painted

$35.51 Subassembly H Bracket, HV H Bracket, HV Cable to Trans, H Bracket, HV 3.0000 sec 3.0000 sec - $0.03 1

Cable to Trans, Washed Cable to Trans, 

Painted Washed

$35.51 Tool H Bracket, HV Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cable to Trans, 

Washed

$42.18 Subassembly H Bracket, HV H Bracket, HV Cable to Trans, H Bracket, HV 3.0000 sec 3.0000 sec - $0.03 1

Cable to Trans, Welded Cable to Trans, 

Washed Welded

$42.18 Tool H Bracket, HV Projection Welder 3.0000 sec 3.0000 sec $0.00 $0.04 1

Cable to Trans, 

Welded

$42.18 P.-P. Part H Bracket, HV H Bracket, HV Cable to Trans, H Bracket, HV 3.0000 sec 3.0000 sec - $0.04 1

Cable to Trans, Engraved Cable to Trans, 

Welded Engraved

$42.18 Tool H Bracket, HV Label Engraver 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cable to Trans, 

Engraved

$42.91 P.-P. Part H Bracket, HV H Bracket, HV Cable to Trans, H Bracket, HV 3.0000 sec 3.0000 sec - $0.04 1

Cable to Trans, Stamped Cable to Trans, 

Engraved Stamped

Design Profit ®

Page 1 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$42.91 Tool H Bracket, HV Stamping Press 200-400 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cable to Trans, 

Stamped

$42.91 Part H Bracket, HV H Bracket, HV Cable to Trans, H Bracket, HV 0.0000 sec 1.8000 sec $0.87 $0.02 1

Cable to Trans, Material Cable to Trans, 

Stamped Material

- - - Blank weight 1.942 lbs - - - - - -

- - - Press Size: 300 Ton Progressive - - - - - -

- - - Part Size after stamping (185L x - - - - - -

125W x 55H)mm

- - - Engrave 32 Characters 0.5 - - - - - -

sec/each

$42.18 Material Mod. H Bracket, HV Engrave 4.0000 sec 16.0000 sec $0.00 $0.19 1

Cable to Trans, 

Engraved

$42.18 Operation H Bracket, HV Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Cable to Trans, 

Welded

$42.18 Part H Bracket, HV H Weld Nut, Bracket HV Cable to H Weld Nut, 4.0000 sec 4.0000 sec $0.01 $0.05 1

Cable to Trans, Trans, 6mm Square Bracket HV Cable 

Welded to Trans, 6mm 

Square

$42.18 Fastening H Bracket, HV Projection Weld 3.0000 sec 3.0000 sec $0.00 $0.04 1

Cable to Trans, 

Welded

$42.18 Operation H Bracket, HV Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Cable to Trans, 

Welded

- - - In-Line Washer - - - - - -

$35.51 Operation H Bracket, HV Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Cable to Trans, 

Washed

$35.51 Operation H Bracket, HV Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.05 1

Cable to Trans, 

Washed

$35.51 Operation H Bracket, HV Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Cable to Trans, 

Washed

- - - Spray - - - - - -

$35.51 Operation H Bracket, HV Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Cable to Trans, 

Painted

Design Profit ®

Page 2 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$35.51 Operation H Bracket, HV Paint Part Medium 5.0000 sec 5.0000 sec $0.00 $0.05 1

Cable to Trans, 

Painted

$28.80 P.-P. Part H Bracket Asm, H Bracket Clip, HV Cable to H Bracket Clip, 6.0000 sec 6.0000 sec - $0.06 1

HV Cable to Trans HV Cable to 

Trans Trans

$28.80 Tool H Bracket Clip, Injection Molding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

HV Cable to 200-400 Ton

Trans

$28.80 Part H Bracket Clip, H Bracket Clip, HV Cable to H Bracket Clip, 0.0000 sec 1.4430 sec $0.07 $0.01 1

HV Cable to Trans, Material HV Cable to 

Trans Trans, Material

- - - Raw Material Req 0.038 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 110mm L x 43.2mm W - - - - - -

x 26.4mm H

$35.51 Fastening H Bracket Asm, Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 1

HV Cable to 

Trans

$83.31 Part H Traction & HV H Bolt Trans Cable Bracket H Bolt Trans 3.0000 sec 3.0000 sec $0.15 $0.07 2

Power Cable Bracket

Distribution Sub

$83.31 Tool H Traction & HV Power Tool 4.0000 sec 4.0000 sec $0.00 $0.09 1

Power 

Distribution Sub

$83.31 Fastening H Traction & HV Power Screw 4.0000 sec 4.0000 sec $0.00 $0.09 2

Power 

Distribution Sub

$83.31 Operation H Traction & HV CDI 1.0000 sec 1.0000 sec $0.00 $0.02 1

Power 

Distribution Sub

- - - High Voltage cable routing In - - - - - -

Engine Compartment

$35.51 Subassembly H Traction & HV H Bracket Asm, HV Cable Dash H Bracket Asm, 9.0000 sec 9.0000 sec - $0.21 1

Power HV Cable Dash

Distribution Sub

$35.51 Tool H Bracket Asm, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

HV Cable Dash

$35.51 Subassembly H Bracket Asm, H Bracket, HV Cable to Dash, H Bracket, HV 3.0000 sec 3.0000 sec - $0.03 1

HV Cable Dash Painted Cable to Dash, 

Painted

Design Profit ®

Page 3 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$35.51 Tool H Bracket, HV First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cable to Dash, 

Painted

$20.81 Subassembly H Bracket, HV H Bracket, HV Cable to Dash, H Bracket, HV 3.0000 sec 3.0000 sec - $0.03 1

Cable to Dash, Washed Cable to Dash, 

Painted Washed

$20.81 Tool H Bracket, HV Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cable to Dash, 

Washed

$42.18 Subassembly H Bracket, HV H Bracket, HV Cable to Dash, H Bracket, HV 3.0000 sec 3.0000 sec - $0.02 1

Cable to Dash, Welded Cable to Dash, 

Washed Welded

$42.18 Tool H Bracket, HV Spot Weld Fixture 3.0000 sec 3.0000 sec $0.00 $0.04 1

Cable to Dash, 

Welded

$24.60 P.-P. Part H Bracket, HV H Bracket Main, HV Cable to H Bracket Main, 3.0000 sec 3.0000 sec - $0.04 1

Cable to Dash, Dash, Stamped HV Cable to 

Welded Dash, Stamped

$24.60 Tool H Bracket Main, Stamping Press 60-200 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

HV Cable to 

Dash, Stamped

$24.60 Part H Bracket Main, H Bracket Main, H Bracket Main, HV Cable to H Bracket Main, HV Cable to H Bracket Main, H Bracket Main, 0.0000 sec 0.0000 sec 1.7000 sec 1.7000 sec $0.18 $0.01 1

HV Cable to Dash, Material HV Cable to 

Dash, Stamped Dash, Material

- - - Blank weight 0.397 lbs - - - - - -

- - - Press Size: 200 Ton Progressive - - - - - -

- - - Part Size after stamping (168L x - - - - - -

80W x 14H)mm

$42.18 P.-P. Part H Bracket, HV H Bracket Stiffener, HV Cable to H Bracket 5.0000 sec 5.0000 sec - $0.06 1

Cable to Dash, Dash, Engraved Stiffener, HV 

Welded Cable to Dash, 

Engraved

$42.18 Tool H Bracket Label Engraver 0.0000 sec 0.0000 sec $0.00 $0.00 1

Stiffener, HV 

Cable to Dash, 

Engraved

$15.50 P.-P. Part H Bracket H Bracket Stiffener, HV Cable to H Bracket 5.0000 sec 5.0000 sec - $0.06 1

Stiffener, HV Dash, Stamped Stiffener, HV 

Cable to Dash, Cable to Dash, 

Engraved Stamped

Design Profit ®

Page 4 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$15.50 Tool H Bracket Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Stiffener, HV 

Cable to Dash, 

Stamped

$15.50 Part H Bracket H Bracket Stiffener, HV Cable to H Bracket 0.0000 sec 0.6000 sec $0.16 $0.00 1

Stiffener, HV Dash, Stamped Stiffener, HV 

Cable to Dash, Cable to Dash, 

Stamped Material

- - - Blank weight 0.357 lbs - - - - - -

- - - Press Size: 25 Ton Progressive - - - - - -

- - - Part Size after stamping (111L x - - - - - -

68W x 14H)mm

- - - Engrave 25 Characters 0.5 - - - - - -

sec/each

$42.18 Material Mod. H Bracket Engrave 4.0000 sec 12.5000 sec $0.00 $0.15 1

Stiffener, HV 

Cable to Dash, 

Engraved

$42.18 Fastening H Bracket, HV Spot Weld 3.0000 sec 3.0000 sec $0.00 $0.04 4

Cable to Dash, 

Welded

- - - In-Line W In-Line Washer - - - - - -

$20.81 Operation H Bracket, HV Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 1

Cable to Dash, 

Washed

$20.81 Operation H Bracket, HV Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.03 1

Cable to Dash, 

Washed

$20.81 Operation H Bracket, HV Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Cable to Dash, 

Washed

- - - Spray - - - - - -

$35.51 Operation H Bracket, HV Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Cable to Dash, 

Painted

$35.51 Operation H Bracket, HV Paint Part Medium 5.0000 sec 5.0000 sec $0.00 $0.05 1

Cable to Dash, 

Painted

$35.51 Subassembly H Bracket Asm, H Bushing Asm, Dash Bracket H Bushing Asm, 6.0000 sec 6.0000 sec - $0.06 3

HV Cable Dash Asm Dash Bracket 

Asm

Design Profit ®

Page 5 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$35.51 Tool H Bushing Asm, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 3

Dash Bracket 

Asm

$16.39 P.-P. Part H Bushing Asm, H Bushing, Dash Bracket Asm, H Bushing, Dash 3.0000 sec 3.0000 sec - $0.03 3

Dash Bracket Molded Bracket Asm

Asm

$16.39 Tool H Bushing, Dash Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 3

Bracket Asm, ton

Molded

$16.39 Part H Bushing, Dash H Bushing, Dash Bracket Asm, H Bushing, Dash 0.0000 sec 9.5340 sec $0.02 $0.04 3

Bracket Asm, Material Bracket Asm, 

Molded Material

- - - Raw Material Req 0.014 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 23mm L x 23mm W x - - - - - -

15mm H

$42.18 P.-P. Part H Bushing Asm, H Anti Crush Insert, Dash Bracket H Anti Crush 6.0000 sec 6.0000 sec - $0.06 3

Dash Bracket Asm, Painted Insert, Dash 

Asm Bracket Asm, 

Painted

$42.18 Tool H Anti Crush H Anti Crush First Fixture First Fixture 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 3

Insert, Dash 

Bracket Asm, 

Painted

$10.75 P.-P. Part H Anti Crush H Anti Crush Insert, Dash Bracket H Anti Crush 3.0000 sec 3.0000 sec - $0.04 3

Insert, Dash Asm, Washed Insert, Dash 

Bracket Asm, Bracket Asm, 

Painted Washed

$10.75 Tool H Anti Crush Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 3

Insert, Dash DRY

Bracket Asm, 

Washed

$15.50 P.-P. Part H Anti Crush H Anti Crush Insert, Dash Bracket H Anti Crush 3.0000 sec 3.0000 sec - $0.01 3

Insert, Dash Asm, Stamped Insert, Dash 

Bracket Asm, Bracket Asm, 

Washed Stamped

$15.50 Tool H Anti Crush Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 3

Insert, Dash 

Bracket Asm, 

Stamped

Design Profit ®
Page 

6 of 53

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$15.50 Part H Anti Crush H Anti Crush Insert, Dash Bracket H Anti Crush 0.0000 sec 0.6000 sec $0.01 $0.00 3

Insert, Dash Asm, Material Insert, Dash 

Bracket Asm, Bracket Asm, 

Stamped Material

- - - Blank weight 0.014 lbs - - - - - -

- - - Press Size: 25 Ton Progressive - - - - - -

- - - Part Size after stamping (23 L x - - - - - -

23 W x 12 H)mm

- - - Batch Type Washer - - - - - -

- - - 5-10 min cycle time - - - - - -

- - - Basket Size 15.75x18.50x25.50 - - - - - -

inches x 2

$10.75 Operation H Anti Crush Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 3

Insert, Dash 

Bracket Asm, 

Washed

$10.75 Operation H Anti Crush Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 3

Insert, Dash 

Bracket Asm, 

Washed

$10.75 Operation H Anti Crush Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 3

Insert, Dash 

Bracket Asm, 

Washed

- - - Spray - - - - - -

$42.18 Operation H Anti Crush Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 3

Insert, Dash 

Bracket Asm, 

Painted

$42.18 Operation H Anti Crush Paint Part Small 3.0000 sec 3.0000 sec $0.00 $0.04 3

Insert, Dash 

Bracket Asm, 

Painted

$35.51 Fastening H Bushing Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 3

Dash Bracket 

Asm

$35.51 Fastening H Bracket Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

HV Cable Dash

$35.51 Operation H Bracket Asm, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

HV Cable Dash

$35.51 Fastening H Bracket Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 1

HV Cable Dash

Design Profit ®

Page 7 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$83.31 Part H Traction & HV H Bolt Bracket front of dash H Bolt Bracket 6.0000 sec 6.0000 sec $0.06 $0.14 3

Power front of dash

Distribution Sub

$83.31 Tool H Traction & HV Power Tool 4.0000 sec 4.0000 sec $0.00 $0.09 1

Power 

Distribution Sub

$83.31 Fastening H Traction & HV Power Screw 4.0000 sec 4.0000 sec $0.00 $0.09 3

Power 

Distribution Sub

$29.69 Subassembly H Traction & HV H Cable Asm, High Voltage H Cable 15.0000 sec 15.0000 sec - $0.35 1

Power Assembly High 

Distribution Sub Voltage

$29.69 Tool H Cable Asm, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

High Voltage

$29.69 Subassembly H Cable Asm, H Cable Asm, HV, Covered H Cable 7.0000 sec 7.0000 sec - $0.06 1

High Voltage Assembly High 

Voltage, Covered

$29.69 Tool H Cable Asm, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

HV, Covered

$29.69 Subassembly H Cable Asm, H HV Harn Asm, w/JB & Tape H HV Harness 7.0000 sec 7.0000 sec - $0.06 1

HV, Covered Asm, with JB & 

Tape

$29.69 Tool H HV Harn Asm, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

w/JB & Tape

$29.69 Subassembly H HV Harn Asm, H HV Harn Asm, w/ Tape & H HV Harn Asm, 7.0000 sec 7.0000 sec - $0.06 1

w/JB & Tape Connectors w/ Tape & 

Connectors

$29.69 Tool H HV Harn Asm, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

w/ Tape & 

Connectors

$29.69 Subassembly H HV Harn Asm, H HV Harn Asm, w/ Tape & H HV Harn Asm, 7.0000 sec 7.0000 sec #### $0.06 1

w/ Tape & Terminals w/ Tape & 

Connectors Terminals

$29.69 Tool H HV Harn Asm, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

w/ Tape & 

Terminals

- - - 304" - 5.49mm Shielded Cable = - - - - - -

$152.00

- - - 4 - Conn Seals, Large $0.384 - - - - - -

- - - 4 - Grnd Caps & Ferrules $0.096 - - - - - -

- - - 4 - 5.5mm Female Terminals: - - - - - -

$0.40

Design Profit ®

Page 8 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - 4 Terminal Align Guides: $0.12 - - - - - -

- - - 466" - 2.72mm Shielded Cable = - - - - - -

$93.20

- - - 2 - Conn Caps $0.40 - - - - - -

- - - 6 - Conn Seals $0.66 - - - - - -

- - - 12 - Grnd Caps & Ferrules - - - - - -

$0.22

- - - 6 - JB Seal Keepers $0.234 - - - - - -

- - - 6 - JB Conn Seals $0.63 - - - - - -

- - - 12 - 2.8mm Female Terminals: - - - - - -

$0.30

- - - 730" - 18 Gauge Wire = $1.2167 - - - - - -

- - - 3 - 2 Cav 1.5mm Seal, Conn, - - - - - -

TPA: $0.297

- - - 6 - 1.5mm Female Spade Terms - - - - - -

& Seals: $0.17

- - - 4 - 1.0mm Male Spade Terms & - - - - - -

Seals: $0.15

- - - 4.5" - 13mm Adhesive - - - - - -

Heatshrink: $0.0525

- - - 5" - 3/8" Butyl Strip Caulk: 5" - 3/8" Butyl Strip Caulk: - - - - - -

$0.05

- - - 3" - 25mm Orange Convolute: - - - - - -

$0.04

- - - 35" - 19mm Orange Convolute: - - - - - -

$0.35

- - - 51" - 16mm Orange Convolute: - - - - - -

$0.38

- - - 3 Standard Tape-on Clips $0.09 - - - - - -

- - - 1 Large Tape-on Clip $0.06 - - - - - -

- - - 2 - Strap on Clips $0.09 - - - - - -

- - - 1 - Tape-on Label: $0.10 - - - - - -

- - - 1,467" - 3/4" Orange Tape: - - - - - -

$1.22

- - - 17" - 3/4" Black Tape: $0.0142 - - - - - -

- - - 75" - 3/4" Black Duct Tape: - - - - - -

$0.09

- - - 13.5" - 1" Black Fabric Tape: - - - - - -

$0.02

Design Profit ®

Page 9 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - 18" - 80mm Wide Foil & Mesh - - - - - -

Tape: $1.2570

- - - Install Pass-thru Boot & Mount - - - - - -

$90.59 P.-P. Part H HV Harn Asm, H HV Cable Boot, Molded H HV Cable Boot, 10.0000 sec 10.0000 sec - $0.08 1

w/ Tape & Molded

Connectors

$90.59 Tool H HV Cable Boot, Inj Molding Machine 800-1500 0.0000 sec 0.0000 sec $0.00 $0.00 1

Molded Ton

$90.59 Part H HV Cable Boot, H HV Cable Boot, Material H HV Cable Boot, 0.0000 sec 6.6260 sec $0.66 $0.17 1

Molded Material

- - - Raw Material Req 0.360 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 159mm L x 137mm W x - - - - - -

115mm H

$29.69 Fastening H HV Harn Asm, Push Wire In 3.0000 sec 3.0000 sec $0.00 $0.02 6

w/ Tape & 

Connectors

$29.69 Operation H HV Harn Asm, 18" Move 2.0000 sec 2.0000 sec $0.00 $0.02 3

w/ Tape & 

Connectors

$28.80 Subassembly Subassembly H HV Harn Asm, H HV Harn Asm, H HV Cable Boot Mount Asm H HV Cable Boot Mount Asm H HV Cable Boot H HV Cable Boot 9.0000 sec 9.0000 sec 9.0000 sec 9.0000 sec - $0.07 1

w/ Tape & Mount Asm

Connectors

$28.80 Tool H HV Cable Boot Inj Molding Machine 400-800 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Mount Asm

$28.80 Part H HV Cable Boot H HV Boot Mount Bolt H HV Boot Mount 3.0000 sec 3.0000 sec $0.00 $0.02 3

Mount Asm Bolt

$28.80 Fastening H HV Cable Boot Set In Place 1.0000 sec 1.0000 sec $0.00 $0.01 3

Mount Asm

$28.80 Part H HV Cable Boot H HV Cable Boot Mount, Material H HV Cable Boot 0.0000 sec 1.5540 sec $0.18 $0.01 1

Mount Asm Mount, Material

- - - Raw Material Req 0.105 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 146mm L x 123mm W x - - - - - -

30mm H

$29.69 Fastening H HV Harn Asm, Push Wire In 3.0000 sec 3.0000 sec $0.00 $0.02 3

w/ Tape & 

Connectors

Design Profit ®

Page 10 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$29.69 Operation H HV Harn Asm, 18" Move 2.0000 sec 2.0000 sec $0.00 $0.02 3

w/ Tape & 

Connectors

$29.69 Part H HV Harn Asm, H Wrap Tie, HV Harness Mount H Wrap Tie, HV 12.0000 sec 12.0000 sec $0.01 $0.10 1

w/ Tape & Harness Mount

Connectors

$29.69 Tool H HV Harn Asm, Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.02 1

w/ Tape & 

Connectors

$29.69 Fastening H HV Harn Asm, Trim to Length 1.0000 sec 1.0000 sec $0.00 $0.01 1

w/ Tape & 

Connectors

$29.69 Operation H HV Harn Asm, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

w/ Tape & 

Connectors

- - - Install Med HV Conn for A/C Mod - - - - - -

$29.69 Multitouch H HV Harn Asm, H Regrab HV Harness H Regrab HV 12.0000 sec 12.0000 sec $0.00 $0.10 1

w/ Tape & Harness

Connectors

$29.69 Subassembly H HV Harn Asm, H HV Medium Conn Asm, A/C H HV Medium 7.0000 sec 7.0000 sec - $0.06 1

w/ Tape & Mod Conn Asm

Connectors

$29.69 Tool H HV Medium First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Conn Asm, A/C 

Mod

$28.80 P.-P. Part H HV Medium H HV Medium Conn Body, H HV Medium 3.0000 sec 3.0000 sec - $0.02 1

Conn Asm, A/C Molded Conn Body, 

Mod Molded

$28.80 Tool H HV Medium Injection Molding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Conn Body, 200-400 Ton

Molded

$28.80 Part H HV Medium H HV Medium Conn Body, H HV Medium 0.0000 sec 1.3090 sec $0.32 $0.01 1

Conn Body, Material Conn Body, 

Molded Material

- - - Raw Material Req 0.072 lbs from - - - - - -

Cost Sheet

- - - 12 Cavity Mold - - - - - -

- - - Box Size 58mm L x 54mm W x - - - - - -

37mm H

$10.75 P.-P. Part H HV Medium H HV Medium Conn Shield H HV Medium 5.0000 sec 5.0000 sec - $0.04 2

Conn Asm, A/C Conn Shield

Mod

Design Profit ®

Page 11 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$10.75 Tool H HV Medium Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 2

Conn Shield DRY

$15.50 P.-P. Part H HV Medium H HV Medium Conn Shield, H HV Medium 3.0000 sec 3.0000 sec - $0.01 4

Conn Shield Stamped Conn Shield, 

Stamped

$15.50 Tool H HV Medium Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 4

Conn Shield, 

Stamped

$15.50 Part H HV Medium H HV Medium Conn Shield, H HV Medium 0.0000 sec 0.6000 sec $0.01 $0.00 8

Conn Shield, Material Conn Shield, 

Stamped Material

- - - Blank weight 0.090 lbs - - - - - -

- - - Press Size 25 Ton Progressive - - - - - -

- - - Part Size after stamping (44. L x - - - - - -

13 W x 13 H)mm

$10.75 Operation H HV Medium Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 2

Conn Shield

$10.75 Operation H HV Medium Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 2

Conn Shield

$10.75 Operation H HV Medium Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 2

Conn Shield

$29.69 Fastening Fastening H HV Medium H HV Medium Push In Place Push In Place 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec $0.00 $0.02 2

Conn Asm, A/C 

Mod

$29.69 Operation H HV Medium CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Conn Asm, A/C 

Mod

$16.39 P.-P. Part H HV Medium H HV Seal, Medium Conn, H HV Seal, 10.0000 sec 10.0000 sec - $0.08 2

Conn Asm, A/C Molded Medium Conn, 

Mod Molded

$16.39 Tool H HV Seal, Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 2

Medium Conn, ton

Molded

$16.39 Part H HV Seal, H HV Seal, Medium Conn, H HV Seal, 0.0000 sec 0.9570 sec $0.01 $0.00 4

Medium Conn, Material Medium Conn, 

Molded Material

- - - Raw Material Req 0.004 lbs from - - - - - -

Cost Sheet

- - - 14 Cavity Mold - - - - - -

- - - Box Size 22mm L x 22mm W x - - - - - -

13mm H

Design Profit ®

Page 12 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$29.69 Fastening H HV Medium Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

Conn Asm, A/C 

Mod

$29.69 Fastening H HV Harn Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

w/ Tape & 

Connectors

$29.69 Operation H HV Harn Asm, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

w/ Tape & 

Connectors

$29.69 Part H HV Harn Asm, H HV TPA, Medium Conn H HV TPA, 8.0000 sec 8.0000 sec $0.03 $0.07 2

w/ Tape & Medium Conn

Connectors

$29.69 Fastening H HV Harn Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

w/ Tape & 

Connectors

$29.69 Multitouch H HV Harn Asm, H Regrab Small Connector H Regrab Small 11.0000 sec 11.0000 sec $0.00 $0.09 1

w/ Tape & Connector

Connectors

$29.69 Fastening H HV Harn Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 1

w/ Tape & 

Connectors

$29.69 Operation Operation H HV Harn Asm, H HV Harn Asm, CDI 1.0000 sec 1.0000 sec 1.0000 sec 1.0000 sec $0.00 $0.01 1

w/ Tape & 

Connectors

$28.80 P.-P. Part H HV Harn Asm, H HV Cable Clamp Base, Med, H HV Cable 9.0000 sec 9.0000 sec - $0.07 1

w/ Tape & Curved, Molded Clamp Base, 

Connectors Med, Curved, 

Molded

$28.80 Tool H HV Cable Injection Molding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Clamp Base, 200-400 Ton

Med, Curved, 

Molded

$28.80 Part H HV Cable H HV Cable Clamp Base, Med, H HV Cable 0.0000 sec 0.8700 sec $0.03 $0.01 1

Clamp Base, Curved, Material Clamp Base, 

Med, Curved, Med, Curved, 

Molded Material

- - - Raw Material Req 0.018 lbs from - - - - - -

Cost Sheet

- - - 12 Cavity Mold - - - - - -

- - - Box Size 53mm L x 55mm W x - - - - - -

26mm H

Design Profit ®
Page 13 of 53

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$28.80 P.-P. Part H HV Harn Asm, H HV Cable Clamp Cover, Med, H HV Cable 9.0000 sec 9.0000 sec - $0.07 1

w/ Tape & Curved, Molded Clamp Cover, 

Connectors Med, Curved, 

Molded

$28.80 Tool H HV Cable Injection Molding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Clamp Cover, 200-400 Ton

Med, Curved, 

Molded

$28.80 Part H HV Cable H HV Cable Clamp Cover, Med, H HV Cable 0.0000 sec 0.8810 sec $0.03 $0.01 1

Clamp Cover, Curved, Material Clamp Cover, 

Med, Curved, Med, Curved, 

Molded Material

- - - Raw Material Req 0.020 lbs from - - - - - -

Cost Sheet

- - - 12 Cavity Mold - - - - - -

- - - Box Size 56mm L x 49mm W - - - - - -

x36mm H

$29.69 Fastening H HV Harn Asm, Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 2

w/ Tape & 

Connectors

- - - Install Med HV Conn for DC-DC - - - - - -

$29.69 Multitouch Multitouch H HV Harn Asm, H HV Harn Asm, H Regrab HV Harness H Regrab HV Harness H Regrab HV H Regrab HV 12.0000 sec 12.0000 sec 12.0000 sec 12.0000 sec $0.00 $0.10 1

w/ Tape & Harness

Connectors

$29.69 Subassembly H HV Harn Asm, H HV Medium Conn Asm, DC-DC H HV Medium 7.0000 sec 7.0000 sec - $0.06 1

w/ Tape & Conv Conn Asm

Connectors

$29.69 Tool H HV Medium First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Conn Asm, 

DC-DC Conv

$28.80 P.-P. Part H HV Medium H HV Medium Conn Body, H HV Medium 3.0000 sec 3.0000 sec - $0.02 1

Conn Asm, Molded Conn Body, 

DC-DC Conv Molded

$28.80 Tool H HV Medium Injection Molding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Conn Body, 200-400 Ton

Molded

$28.80 Part H HV Medium H HV Medium Conn Body, H HV Medium 0.0000 sec 1.3090 sec $0.32 $0.01 1

Conn Body, Material Conn Body, 

Molded Material

- - - Raw Material Req 0.072 lbs from - - - - - -

Cost Sheet

- - - 12 Cavity Mold - - - - - -

Design Profit ®

Page 14 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Box Size 58mm L x 54mm W x - - - - - -

37mm H

$10.75 P.-P. Part H HV Medium H HV Medium Conn Shield H HV Medium 5.0000 sec 5.0000 sec - $0.04 2

Conn Asm, Conn Shield

DC-DC Conv

$10.75 Tool H HV Medium Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 2

Conn Shield DRY

$15.50 P.-P. Part H HV Medium H HV Medium Conn Shield, H HV Medium 3.0000 sec 3.0000 sec - $0.01 4

Conn Shield Stamped Conn Shield, 

Stamped

$15.50 Tool H HV Medium Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 4

Conn Shield, 

Stamped

$15.50 Part H HV Medium H HV Medium Conn Shield, H HV Medium 0.0000 sec 0.6000 sec $0.01 $0.00 8

Conn Shield, Material Conn Shield, 

Stamped Material

- - - Blank weight 0.090 lbs - - - - - -

- - - Press Size 25 Ton Progressive - - - - - -

- - - Part Size after stamping (44. L x - - - - - -

13 W x 13 H)mm

$10.75 Operation H HV Medium Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 2

Conn Shield

$10.75 Operation H HV Medium Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 2

Conn Shield

$10.75 Operation H HV Medium Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 2

Conn Shield

$29.69 Fastening H HV Medium Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

Conn Asm, 

DC-DC Conv

$29.69 Operation H HV Medium CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Conn Asm, 

DC-DC Conv

$16.39 P.-P. Part H HV Medium H HV Seal, Medium Conn, H HV Seal, 10.0000 sec 10.0000 sec - $0.08 2

Conn Asm, Molded Medium Conn, 

DC-DC Conv Molded

$16.39 Tool H HV Seal, Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 2

Medium Conn, ton

Molded

$16.39 Part H HV Seal, H HV Seal, Medium Conn, H HV Seal, 0.0000 sec 0.9570 sec $0.01 $0.00 4

Medium Conn, Material Medium Conn, 

Molded Material

Design Profit ®

Page 15 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Raw Material Req 0.004 lbs from - - - - - -

Cost Sheet

- - - 14 Cavity Mold - - - - - -

- - - Box Size 22mm L x 22mm W x - - - - - -

13mm H

$29.69 Fastening H HV Medium Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

Conn Asm, 

DC-DC Conv

$29.69 Fastening H HV Harn Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

w/ Tape & 

Connectors

$29.69 Operation H HV Harn Asm, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

w/ Tape & 

Connectors

$29.69 Part H HV Harn Asm, H HV TPA, Medium Conn H HV TPA, 8.0000 sec 8.0000 sec $0.03 $0.07 2

w/ Tape & Medium Conn

Connectors

$29.69 Fastening H HV Harn Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

w/ Tape & 

Connectors

$29.69 Multitouch H HV Harn Asm, H Regrab Small Connector H Regrab Small 11.0000 sec 11.0000 sec $0.00 $0.09 1

w/ Tape & Connector

Connectors

$29.69 Fastening H HV Harn Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 1

w/ Tape & 

Connectors

$29.69 Operation H HV Harn Asm, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

w/ Tape & 

Connectors

$28.80 P.-P. Part H HV Harn Asm, H HV Cable Clamp Base, Med, H HV Cable 9.0000 sec 9.0000 sec - $0.07 1

w/ Tape & Straight, Molded Clamp Base, 

Connectors Med, Straight, 

Molded

$28.80 Tool H HV Cable Injection Molding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Clamp Base, 200-400 Ton

Med, Straight, 

Molded

$28.80 Part H HV Cable H HV Cable Clamp Base, Med, H HV Cable 0.0000 sec 0.8710 sec $0.03 $0.01 1

Clamp Base, Straight, Material Clamp Base, 

Med, Straight, Med, Straight, 

Molded Material

- - - Raw Material Req 0.017 lbs from - - - - - -

Cost Sheet

Design Profit ®
Page 16 of 53

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - 12 Cavity Mold - - - - - -

- - - Box Size 52mm L x 46mm W x - - - - - -

26mm H

$28.80 P.-P. Part H HV Harn Asm, H HV Cable Clamp Cover, Med, H HV Cable 9.0000 sec 9.0000 sec - $0.07 1

w/ Tape & Straight, Molded Clamp Cover, 

Connectors Med, Straight, 

Molded

$28.80 Tool H HV Cable Injection Molding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Clamp Cover, 200-400 Ton

Med, Straight, 

Molded

$28.80 Part H HV Cable H HV Cable Clamp Cover, Med, H HV Cable 0.0000 sec 0.8740 sec $0.03 $0.01 1

Clamp Cover, Straight, Material Clamp Cover, 

Med, Straight, Med, Straight, 

Molded Material

- - - Raw Material Req 0.020 lbs from - - - - - -

Cost Sheet

- - - 12 Cavity Mold - - - - - -

- - - Box Size 59mm L x 49mm W - - - - - -

x36mm H

$29.69 Fastening H HV Harn Asm, Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 2

w/ Tape & 

Connectors

- - - Install Med HV Conn for BEC - - - - - -

$29.69 Multitouch H HV Harn Asm, H Regrab HV Harness H Regrab HV 12.0000 sec 12.0000 sec $0.00 $0.10 1

w/ Tape & Harness

Connectors

$29.69 Subassembly H HV Harn Asm, H HV Medium Conn Asm, BEC H HV Medium 7.0000 sec 7.0000 sec - $0.06 1

w/ Tape & Module Conn Asm

Connectors

$29.69 Tool H HV Medium First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Conn Asm, BEC 

Module

$28.80 P.-P. Part H HV Medium H HV Medium Conn Body, H HV Medium 3.0000 sec 3.0000 sec - $0.02 1

Conn Asm, BEC Molded Conn Body, 

Module Molded

$28.80 Tool H HV Medium Injection Molding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Conn Body, 200-400 Ton

Molded

$28.80 Part H HV Medium H HV Medium Conn Body, H HV Medium 0.0000 sec 1.3090 sec $0.32 $0.01 1

Conn Body, Material Conn Body, 

Molded Material

Design Profit ®

Page 17 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Raw Material Req 0.072 lbs from - - - - - -

Cost Sheet

- - - 12 Cavity Mold - - - - - -

- - - Box Size 58mm L x 54mm W x - - - - - -

37mm H

$10.75 P.-P. Part H HV Medium H HV Medium Conn Shield H HV Medium 5.0000 sec 5.0000 sec - $0.04 2

Conn Asm, BEC Conn Shield

Module

$10.75 Tool H HV Medium Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 2

Conn Shield DRY

$15.50 P.-P. Part H HV Medium H HV Medium Conn Shield, H HV Medium 3.0000 sec 3.0000 sec - $0.01 4

Conn Shield Stamped Conn Shield, 

Stamped

$15.50 Tool H HV Medium Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 4

Conn Shield, 

Stamped

$15.50 Part H HV Medium H HV Medium Conn Shield, H HV Medium 0.0000 sec 0.6000 sec $0.01 $0.00 8

Conn Shield, Material Conn Shield, 

Stamped Material

- - - Blank weight 0.090 lbs - - - - - -

- - - Press Size 25 Ton Progressive - - - - - -

- - - Part Size after stamping (44. L x Part Size after stamping (44. L x - - - - - -

13 W x 13 H)mm

$10.75 Operation H HV Medium Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 2

Conn Shield

$10.75 Operation H HV Medium Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 2

Conn Shield

$10.75 Operation H HV Medium Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 2

Conn Shield

$29.69 Fastening H HV Medium Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

Conn Asm, BEC 

Module

$29.69 Operation H HV Medium CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Conn Asm, BEC 

Module

$16.39 P.-P. Part H HV Medium H HV Seal, Medium Conn, H HV Seal, 10.0000 sec 10.0000 sec - $0.08 2

Conn Asm, BEC Molded Medium Conn, 

Module Molded

$16.39 Tool H HV Seal, Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 2

Medium Conn, ton

Molded

Design Profit ®

Page 18 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$16.39 Part H HV Seal, H HV Seal, Medium Conn, H HV Seal, 0.0000 sec 0.9570 sec $0.01 $0.00 4

Medium Conn, Material Medium Conn, 

Molded Material

- - - Raw Material Req 0.004 lbs from - - - - - -

Cost Sheet

- - - 14 Cavity Mold - - - - - -

- - - Box Size 22mm L x 22mm W x - - - - - -

13mm H

$29.69 Fastening H HV Medium Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

Conn Asm, BEC 

Module

$29.69 Fastening H HV Harn Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

w/ Tape & 

Connectors

$29.69 Operation H HV Harn Asm, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

w/ Tape & 

Connectors

$29.69 Part H HV Harn Asm, H HV TPA, Medium Conn H HV TPA, 8.0000 sec 8.0000 sec $0.03 $0.07 2

w/ Tape & Medium Conn

Connectors

$29.69 Fastening H HV Harn Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

w/ Tape & 

Connectors

$29.69 Multitouch H HV Harn Asm, H Regrab Small Connector H Regrab Small 11.0000 sec 11.0000 sec $0.00 $0.09 1

w/ Tape & Connector

Connectors

$29.69 Fastening H HV Harn Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 1

w/ Tape & 

Connectors

$29.69 Operation H HV Harn Asm, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

w/ Tape & 

Connectors

$29.69 Multitouch H HV Harn Asm, Regrab Cable Clamp for Regrab Cable 7.0000 sec 7.0000 sec $0.00 $0.06 2

w/ Tape & Connector Clamp for 

Connectors Connector

$29.69 Fastening H HV Harn Asm, Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 2

w/ Tape & 

Connectors

- - - Install Large HV Conn for BEC - - - - - -

Conn

$29.69 Multitouch H HV Harn Asm, H Regrab HV Harness H Regrab HV 12.0000 sec 12.0000 sec $0.00 $0.10 1

w/ Tape & Harness

Connectors

Design Profit ®
Page 19 of 53

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$29.69 Subassembly H HV Harn Asm, H HV Large Conn Asm, BEC H HV Large Conn 7.0000 sec 7.0000 sec - $0.06 1

w/ Tape & Module Asm

Connectors

$29.69 Tool H HV Large Conn First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, BEC 

Module

$28.80 P.-P. Part H HV Large Conn H HV Large Conn Body, Molded H HV Large Conn 3.0000 sec 3.0000 sec - $0.02 1

Asm, BEC Body, Molded

Module

$28.80 Tool H HV Large Conn Injection Molding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Body, Molded 200-400 Ton

$28.80 Part H HV Large Conn H HV Large Conn Body, Material H HV Large Conn 0.0000 sec 1.5450 sec $0.74 $0.01 1

Body, Molded Body, Material

- - - Raw Material Req 0.170 lbs from - - - - - -

Cost Sheet

- - - 14 Cavity Mold - - - - - -

- - - Box Size 82mm L x 78mm W x - - - - - -

55mm H

$10.75 P.-P. Part H HV Large Conn H HV Large Conn Shield H HV Large Conn 5.0000 sec 5.0000 sec - $0.04 2

Asm, BEC Shield

Module

$10.75 Tool H HV Large Conn H HV Large Conn Washer Duo 400 W sher Duo 400 Wash Rinse & ash Rinse & 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 2

Shield DRY

$15.50 P.-P. Part H HV Large Conn H HV Large Conn Shield, H HV Large Conn 3.0000 sec 3.0000 sec - $0.01 2

Shield Stamped Shield, Stamped

$15.50 Tool H HV Large Conn Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 2

Shield, Stamped

$15.50 Part H HV Large Conn H HV Large Conn Shield, H HV Large Conn 0.0000 sec 0.6000 sec $0.03 $0.00 2

Shield, Stamped Material Shield, Material

- - - Blank weight 0.020 lbs - - - - - -

- - - Press Size 25 Ton Progressive - - - - - -

- - - Part Size after stamping (66 L x - - - - - -

17 W x 17 H)mm

$10.75 Operation H HV Large Conn Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 2

Shield

$10.75 Operation H HV Large Conn Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 2

Shield

$10.75 Operation H HV Large Conn Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 2

Shield

Design Profit ®

Page 20 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$29.69 Fastening H HV Large Conn Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

Asm, BEC 

Module

$29.69 Operation H HV Large Conn CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, BEC 

Module

$16.39 P.-P. Part H HV Large Conn H HV Seal, Large Conn, Molded H HV Seal, Large 10.0000 sec 10.0000 sec - $0.08 2

Asm, BEC Conn, Molded

Module

$16.39 Tool H HV Seal, Large Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 2

Conn, Molded ton

$16.39 Part H HV Seal, Large H HV Seal, Large Conn, Material H HV Seal, Large 0.0000 sec 1.3960 sec $0.01 $0.01 2

Conn, Molded Conn, Material

- - - Raw Material Req 0.009 lbs from - - - - - -

Cost Sheet

- - - 14 Cavity Mold - - - - - -

- - - Box Size 30mm L x 30mm W x - - - - - -

18mm H

$29.69 Fastening H HV Large Conn Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

Asm, BEC 

Module

$29.69 Operation Operation H HV Large Conn H HV Large Conn CDI 1.0000 sec 1.0000 sec 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, BEC 

Module

$16.39 P.-P. Part H HV Large Conn H HV Large Conn Lock, Molded H HV Large Conn 6.0000 sec 6.0000 sec - $0.05 1

Asm, BEC Lock, Molded

Module

$16.39 Tool H HV Large Conn Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

Lock, Molded ton

$16.39 Part H HV Large Conn H HV Large Conn Lock, Material H HV Large Conn 0.0000 sec 3.4530 sec $0.29 $0.02 1

Lock, Molded Lock, Material

- - - Raw Material Req 0.066 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 85mm L x 78mm W x - - - - - -

44mm H

$29.69 Fastening H HV Large Conn Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 1

Asm, BEC 

Module

$29.69 Fastening H HV Harn Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

w/ Tape & 

Connectors

Design Profit ®

Page 21 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$29.69 Fastening H HV Harn Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

w/ Tape & 

Connectors

$16.39 P.-P. Part H HV Harn Asm, H HV Cable Clamp Base, Large H HV Cable 8.0000 sec 8.0000 sec - $0.07 1

w/ Tape & Conn, Molded Clamp Base, 

Connectors Large Conn, 

Molded

$16.39 Tool H HV Cable Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

Clamp Base, ton

Large Conn, 

Molded

$16.39 Part H HV Cable H HV Cable Clamp Base, Large H HV Cable 0.0000 sec 1.0060 sec $0.10 $0.00 1

Clamp Base, Conn, Material Clamp Base, 

Large Conn, Large Conn, 

Molded Material

- - - Raw Material Req 0.024 lbs from - - - - - -

Cost Sheet

- - - 12 Cavity Mold - - - - - -

- - - Box Size 64mm L x 58mm W x - - - - - -

31mm H

$29.69 Operation H HV Harn Asm, Turn Asm Over 3.0000 sec 3.0000 sec $0.00 $0.02 1

w/ Tape & 

Connectors

$29.69 Multitouch H HV Harn Asm, H Manip Signal Leads, Lrg Conn H Manip Signal 8.0000 sec 8.0000 sec $0.00 $0.07 1

w/ Tape & Leads, Lrg Conn

Connectors

$16.39 P.-P. Part H HV Harn Asm, H HV Cable Clamp Top, Large H HV Cable 8.0000 sec 8.0000 sec - $0.07 1

w/ Tape & Conn, Molded Clamp Top, 

Connectors Large Conn, 

Molded

$16.39 Tool H HV Cable Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

Clamp Top, ton

Large Conn, 

Molded

$16.39 Part H HV Cable H HV Cable Clamp Top, Large H HV Cable 0.0000 sec 0.8610 sec $0.06 $0.01 1

Clamp Top, Conn, Material Clamp Top, 

Large Conn, Large Conn, 

Molded Material

- - - Raw Material Req 0.015 lbs from - - - - - -

Cost Sheet

- - - 12 Cavity Mold - - - - - -

- - - Box Size 66mm L x 20mm W x - - - - - -

14mm H

Design Profit ®
Page 22 of 53

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$29.69 Fastening H HV Harn Asm, Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 1

w/ Tape & 

Connectors

$29.69 Operation H HV Harn Asm, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

w/ Tape & 

Connectors

$29.69 Part H HV Harn Asm, H HV TPA, Lrg Conn, Sig Terms H HV TPA, Lrg 8.0000 sec 8.0000 sec $0.03 $0.07 1

w/ Tape & Conn, Sig Terms

Connectors

$29.69 Fastening H HV Harn Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 1

w/ Tape & 

Connectors

$29.69 Operation H HV Harn Asm, Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.02 1

w/ Tape & 

Connectors

- - - Install Large HV Conn for TCM - - - - - -

Conn

$29.69 Multitouch H HV Harn Asm, H Regrab HV Harness H Regrab HV 12.0000 sec 12.0000 sec $0.00 $0.10 1

w/ Tape & Harness

Connectors

$29.69 Subassembly H HV Harn Asm, H HV Large Conn Asm, TCM H HV Large Conn 7.0000 sec 7.0000 sec - $0.06 1

w/ Tape & Module Asm

Connectors

$29.69 Tool H HV Large Conn First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, TCM 

Module

$28.80 P.-P. Part H HV Large Conn H HV Large Conn Body, Molded H HV Large Conn 3.0000 sec 3.0000 sec - $0.02 1

Asm, TCM Body, Molded

Module

$28.80 Tool H HV Large Conn Injection Molding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Body, Molded 200-400 Ton

$28.80 Part H HV Large Conn H HV Large Conn Body, Material H HV Large Conn 0.0000 sec 1.5450 sec $0.74 $0.01 1

Body, Molded Body, Material

- - - Raw Material Req 0.170 lbs from - - - - - -

Cost Sheet

- - - 14 Cavity Mold - - - - - -

- - - Box Size 82mm L x 78mm W x - - - - - -

55mm H

$10.75 P.-P. Part H HV Large Conn H HV Large Conn Shield H HV Large Conn 5.0000 sec 5.0000 sec - $0.04 2

Asm, TCM Shield

Module

Design Profit ®

Page 23 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$10.75 Tool H HV Large Conn Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 2

Shield DRY

$15.50 P.-P. Part H HV Large Conn H HV Large Conn Shield, H HV Large Conn 3.0000 sec 3.0000 sec - $0.01 2

Shield Stamped Shield, Stamped

$15.50 Tool H HV Large Conn Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 2

Shield, Stamped

$15.50 Part H HV Large Conn H HV Large Conn Shield, H HV Large Conn 0.0000 sec 0.6000 sec $0.03 $0.00 2

Shield, Stamped Material Shield, Material

- - - Blank weight 0.020 lbs - - - - - -

- - - Press Size 60 Ton Progressive - - - - - -

- - - Part Size after stamping (66 L x - - - - - -

17 W x 17 H)mm

$10.75 Operation H HV Large Conn Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 2

Shield

$10.75 Operation H HV Large Conn Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 2

Shield

$10.75 Operation H HV Large Conn Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 2

Shield

$29.69 Fastening H HV Large Conn Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

Asm, TCM 

Module

$29.69 Operation Operation H HV Large Conn H HV Large Conn CDI 1.0000 sec 1.0000 sec 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, TCM 

Module

$16.39 P.-P. Part H HV Large Conn H HV Seal, Large Conn, Molded H HV Seal, Large 10.0000 sec 10.0000 sec - $0.08 2

Asm, TCM Conn, Molded

Module

$16.39 Tool H HV Seal, Large Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 2

Conn, Molded ton

$16.39 Part H HV Seal, Large H HV Seal, Large Conn, Material H HV Seal, Large 0.0000 sec 1.3960 sec $0.01 $0.01 2

Conn, Molded Conn, Material

- - - Raw Material Req 0.009 lbs from - - - - - -

Cost Sheet

- - - 14 Cavity Mold - - - - - -

- - - Box Size 30mm L x 30mm W x - - - - - -

18mm H

$29.69 Fastening H HV Large Conn Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

Asm, TCM 

Module

Design Profit ®

Page 24 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$29.69 Operation H HV Large Conn CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm, TCM 

Module

$16.39 P.-P. Part H HV Large Conn H HV Large Conn Lock, Molded H HV Large Conn 6.0000 sec 6.0000 sec - $0.05 1

Asm, TCM Lock, Molded

Module

$16.39 Tool H HV Large Conn Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

Lock, Molded ton

$16.39 Part H HV Large Conn H HV Large Conn Lock, Material H HV Large Conn 0.0000 sec 3.4530 sec $0.29 $0.02 1

Lock, Molded Lock, Material

- - - Raw Material Req 0.066 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 85mm L x 78mm W x - - - - - -

44mm H

$29.69 Fastening H HV Large Conn Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 1

Asm, TCM 

Module

$29.69 Fastening H HV Harn Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

w/ Tape & 

Connectors

$29.69 Fastening Fastening H HV Harn Asm, H HV Harn Asm, Push In Place Push In Place 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec $0.00 $0.02 2

w/ Tape & 

Connectors

$16.39 P.-P. Part H HV Harn Asm, H HV Cable Clamp Base, Large H HV Cable 8.0000 sec 8.0000 sec - $0.07 1

w/ Tape & Conn, Molded Clamp Base, 

Connectors Large Conn, 

Molded

$16.39 Tool H HV Cable Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

Clamp Base, ton

Large Conn, 

Molded

$16.39 Part H HV Cable H HV Cable Clamp Base, Large H HV Cable 0.0000 sec 1.0060 sec $0.10 $0.00 1

Clamp Base, Conn, Material Clamp Base, 

Large Conn, Large Conn, 

Molded Material

- - - Raw Material Req 0.024 lbs from - - - - - -

Cost Sheet

- - - 12 Cavity Mold - - - - - -

- - - Box Size 64mm L x 58mm W x - - - - - -

31mm H

Design Profit ®

Page 25 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$29.69 Operation H HV Harn Asm, Turn Asm Over 3.0000 sec 3.0000 sec $0.00 $0.02 1

w/ Tape & 

Connectors

$29.69 Multitouch H HV Harn Asm, H Manip Signal Leads, Lrg Conn H Manip Signal 8.0000 sec 8.0000 sec $0.00 $0.07 1

w/ Tape & Leads, Lrg Conn

Connectors

$16.39 P.-P. Part H HV Harn Asm, H HV Cable Clamp Top, Large H HV Cable 8.0000 sec 8.0000 sec - $0.07 1

w/ Tape & Conn, Molded Clamp Top, 

Connectors Large Conn, 

Molded

$16.39 Tool H HV Cable Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

Clamp Top, ton

Large Conn, 

Molded

$16.39 Part H HV Cable H HV Cable Clamp Top, Large H HV Cable 0.0000 sec 0.861 sec $0.06 $0.01 1

Clamp Top, Conn, Material Clamp Top, 

Large Conn, Large Conn, 

Molded Material

- - - Raw Material Req 0.015 lbs from - - - - - -

Cost Sheet

- - - 12 Cavity Mold - - - - - -

- - - Box Size 66mm L x 20mm W Box Size 66mm L x 20mm W x - - - - - -

14mm H

$29.69 Fastening H HV Harn Asm, Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 1

w/ Tape & 

Connectors

$29.69 Operation H HV Harn Asm, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

w/ Tape & 

Connectors

$29.69 Part H HV Harn Asm, H HV TPA, Lrg Conn, Sig Terms H HV TPA, Lrg 8.0000 sec 8.0000 sec $0.03 $0.07 1

w/ Tape & Conn, Sig Terms

Connectors

$29.69 Fastening H HV Harn Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 1

w/ Tape & 

Connectors

$29.69 Operation H HV Harn Asm, Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.02 1

w/ Tape & 

Connectors

- - - Build up HV Junction Block - - - - - -

$29.69 Subassembly H HV Harn Asm, H HV JB Conn Cover Base Asm H HV JB Conn 7.0000 sec 7.0000 sec - $0.06 1

w/JB & Tape Cover Base Asm

Design Profit ®

Page 26 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$29.69 Tool H HV JB Conn First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Base Asm

$16.39 P.-P. Part H HV JB Conn H HV JB Conn Cover Base, H HV JB Conn 3.0000 sec 3.0000 sec - $0.02 1

Cover Base Asm Molded Cover Base, 

Molded

$16.39 Tool H HV JB Conn Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Base, ton

Molded

$16.39 Part H HV JB Conn H HV JB Conn Cover Base, H HV JB Conn 0.0000 sec 1.2950 sec $0.11 $0.01 1

Cover Base, Material Cover Base, 

Molded Material

- - - Raw Material Req 0.074 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 74mm L x 51mm W x - - - - - -

26mm H

$16.39 P.-P. Part H HV JB Conn H HV JB Seal, Conn Cover, H HV JB Seal, 9.0000 sec 9.0000 sec - $0.07 1

Cover Base Asm Molded Conn Cover, 

Molded

$16.39 Tool H HV JB Seal, Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

Conn Cover, ton

Molded

$16.39 Part H HV JB Seal, H HV JB Seal, Conn Cover, H HV JB Seal, 0.0000 sec 3.3040 sec $0.01 $0.02 1

Conn Cover, Material Conn Cover, 

Molded Material

- - - Raw Material Req 0.011 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 66mm L x 44mm W x - - - - - -

9mm H

$29.69 Fastening H HV JB Conn Push Seal in Place 3.0000 sec 3.0000 sec $0.00 $0.02 1

Cover Base Asm

$29.69 Multitouch H HV Harn Asm, Insert HV JB Terminal thru Base Insert HV JB 9.0000 sec 9.0000 sec $0.00 $0.07 6

w/JB & Tape Terminal thru 

Base

$29.69 Subassembly H HV Harn Asm, H HV JB Conn Asm H HV JB Conn 7.0000 sec 7.0000 sec - $0.06 1

w/JB & Tape Asm

$29.69 Tool H HV JB Conn First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm

$16.39 P.-P. Part H HV JB Conn H HV JB Conn Body, Molded H HV JB Conn 3.0000 sec 3.0000 sec - $0.02 1

Asm Body, Molded

Design Profit ®

Page 27 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$16.39 Tool H HV JB Conn Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

Body, Molded ton

$16.39 Part H HV JB Conn H HV JB Conn Body, Material H HV JB Conn 0.0000 sec 1.2260 sec $0.10 $0.01 1

Body, Molded Body, Material

- - - Raw Material Req 0.066 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 51mm L x 26mm W x - - - - - -

43mm H

$10.75 P.-P. Part H HV JB Conn H HV JB Conn Jumper Terminal H HV JB Conn 7.0000 sec 7.0000 sec - $0.06 2

Asm Jumper Terminal

$10.75 Tool H HV JB Conn Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 2

Jumper Terminal DRY

$15.50 P.-P. Part H HV JB Conn H HV JB Conn Jumper Terminal, H HV JB Conn 3.0000 sec 3.0000 sec - $0.01 2

Jumper Terminal Stamped Jumper Terminal, 

Stamped

$15.50 Tool H HV JB Conn Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 2

Jumper Terminal, 

Stamped

$15.50 Part H HV JB Conn H HV JB Conn Jumper Terminal, H HV JB Conn 0.0000 sec 0.6000 sec $0.06 $0.00 2

Jumper Terminal, Material Jumper Terminal, 

Stamped Material

- - - Blank weight 0.013 lbs - - - - - -

- - - Press Size 25 Ton & Progressive - - - - - -

- - - Part Size (45 L x 17 W x 1 H)mm - - - - - -

$10.75 Operation H HV JB Conn Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 2

Jumper Terminal

$10.75 Operation H HV JB Conn Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 2

Jumper Terminal

$10.75 Operation H HV JB Conn Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 2

Jumper Terminal

$29.69 Fastening H HV JB Conn Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

Asm

$16.39 P.-P. Part H HV JB Conn H HV JB Conn Top, Molded H HV JB Conn 5.0000 sec 5.0000 sec - $0.04 1

Asm Top, Molded

$16.39 Tool H HV JB Conn Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

Top, Molded ton

$16.39 Part H HV JB Conn H HV JB Conn Top, Material H HV JB Conn 0.0000 sec 0.7810 sec $0.03 $0.00 1

Top, Molded Top, Material

- - - Raw Material Req 0.018 lbs from - - - - - -

Cost Sheet

Design Profit ®

Page 28 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - 10 Cavity Mold - - - - - -

- - - Box Size 51mm L x 26mm W x - - - - - -

22mm H

$29.69 Fastening H HV JB Conn Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm

$10.75 P.-P. Part H HV JB Conn H HV JB Conn Shield Base H HV JB Conn 3.0000 sec 3.0000 sec - $0.02 1

Asm Shield Base

$10.75 Tool H HV JB Conn Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Shield Base DRY

$29.69 P.-P. Part H HV JB Conn H HV JB Conn Shield Base, H HV JB Conn 3.0000 sec 3.0000 sec - $0.01 1

Shield Base Machined Shield Base, 

Machined

$29.69 Tool H HV JB Conn First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Shield Base, 

Machined

$43.52 P.-P. Part H HV JB Conn H HV JB Conn Shield Base, H HV JB Conn 3.0000 sec 3.0000 sec - $0.02 1

Shield Base, Trimmed Shield Base, 

Machined Trimmed

$43.52 Tool H HV JB Conn Trim Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Shield Base, 

Trimmed

$70.80 P.-P. Part P.-P. Part H HV JB Conn H HV JB Conn H HV JB Conn Shield Base, Die H HV JB Conn Shield Base, Die H HV JB Conn H HV JB Conn 0.0000 sec 0.0000 sec 5.9500 sec 5.9500 sec - $0.07 1

Shield Base, Cast Shield Base, Die 

Trimmed Cast

$70.80 Tool H HV JB Conn Die Casting 0 - 500 ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Shield Base, Die 

Cast

$70.80 Part H HV JB Conn H HV JB Conn Shield Base, H HV JB Conn 0.0000 sec 1.6300 sec $0.05 $0.03 1

Shield Base, Die Material Shield Base, 

Cast Material

- - - Total Material Req'd = 0.039 lbs - - - - - -

- - - 12 Cavity Mold - - - - - -

- - - Box Size 56mm L x 21mm W x - - - - - -

22mm H

$10.75 Operation H HV JB Conn Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Shield Base

$10.75 Operation H HV JB Conn Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 1

Shield Base

$10.75 Operation H HV JB Conn Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Shield Base

$29.69 Fastening H HV JB Conn Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm

Design Profit ®

Page 29 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$29.69 Multitouch H HV Harn Asm, Insert HV JB Terminal into Insert HV JB 11.0000 sec 11.0000 sec $0.00 $0.09 6

w/JB & Tape Connector Terminal into 

Connector

$10.75 P.-P. Part H HV Harn Asm, H HV JB Conn Shield H HV JB Conn 7.0000 sec 7.0000 sec - $0.06 1

w/JB & Tape Shield

$10.75 Tool H HV JB Conn Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Shield DRY

$43.52 P.-P. Part H HV JB Conn H HV JB Conn Shield H HV JB Conn 3.0000 sec 3.0000 sec - $0.01 1

Shield Shield, Trimmed

$43.52 Tool H HV JB Conn Trim Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Shield

$70.80 P.-P. Part H HV JB Conn H HV JB Conn Shield H HV JB Conn 0.0000 sec 6.2400 sec - $0.08 1

Shield Shield, Die Cast

$70.80 Tool H HV JB Conn Die Casting 0 - 500 ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Shield

$70.80 Part H HV JB Conn H HV JB Conn Shield, Material H HV JB Conn 0.0000 sec 1.7100 sec $0.09 $0.03 1

Shield Shield, Material

- - - Total Material Req'd = 0.071 lbs - - - - - -

- - - 12 Cavity Mold - - - - - -

- - - Box Size 58mm L x 60mm W x - - - - - -

17mm H

$10.75 Operation Operation H HV JB Conn H HV JB Conn Load Part Load Part 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec $0.00 $0.01 1

Shield

$10.75 Operation H HV JB Conn Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 1

Shield

$10.75 Operation H HV JB Conn Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Shield

$29.69 Part H HV Harn Asm, H Screw, HV JB Conn Shield H Screw, HV JB 8.0000 sec 8.0000 sec $0.00 $0.07 2

w/JB & Tape Conn Shield

$29.69 Tool H HV Harn Asm, Power Tool 4.0000 sec 4.0000 sec $0.00 $0.03 1

w/JB & Tape

$29.69 Fastening H HV Harn Asm, Power Screw 4.0000 sec 4.0000 sec $0.00 $0.03 2

w/JB & Tape

$29.69 Operation H HV Harn Asm, Turn Asm Over 3.0000 sec 3.0000 sec $0.00 $0.02 1

w/JB & Tape

$10.75 P.-P. Part H HV Harn Asm, H HV JB Conn Shield H HV JB Conn 7.0000 sec 7.0000 sec - $0.06 1

w/JB & Tape Shield

$10.75 Tool H HV JB Conn Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Shield DRY

$43.52 P.-P. Part H HV JB Conn H HV JB Conn Shield H HV JB Conn 3.0000 sec 3.0000 sec - $0.01 1

Shield Shield, Trimmed

Design Profit ®

Page 30 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$43.52 Tool H HV JB Conn Trim Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Shield

$70.80 P.-P. Part H HV JB Conn H HV JB Conn Shield H HV JB Conn 0.0000 sec 6.2400 sec - $0.08 1

Shield Shield, Die Cast

$70.80 Tool H HV JB Conn Die Casting 0 - 500 ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Shield

$70.80 Part H HV JB Conn H HV JB Conn Shield, Material H HV JB Conn 0.0000 sec 1.7100 sec $0.09 $0.03 1

Shield Shield, Material

- - - Total Material Req'd = 0.071 lbs - - - - - -

- - - 12 Cavity Mold - - - - - -

- - - Box Size 58mm L x 60mm W x - - - - - -

17mm H

$10.75 Operation H HV JB Conn Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Shield

$10.75 Operation H HV JB Conn Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 1

Shield

$10.75 Operation H HV JB Conn Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Shield

$29.69 Part H HV Harn Asm, H Screw, HV JB Conn Shield H Screw, HV JB 8.0000 sec 8.0000 sec $0.00 $0.07 2

w/JB & Tape Conn Shield

$29.69 Tool H HV Harn Asm, Power Tool 4.0000 sec 4.0000 sec $0.00 $0.03 1

w/JB & Tape

$29.69 Fastening H HV Harn Asm, Power Screw 4.0000 sec 4.0000 sec $0.00 $0.03 2

w/JB & Tape

$29.69 Operation H HV Harn Asm, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

w/JB & Tape

- - - Seat Cable Seals & Seats - - - - - -

$29.69 Multitouch H HV Harn Asm, Push Cable Seal & Seat in Place Push Cable Seal 8.0000 sec 8.0000 sec $0.00 $0.07 3

w/JB & Tape & Seat in Place

$29.69 Operation H HV Harn Asm, Turn Asm Over 3.0000 sec 3.0000 sec $0.00 $0.02 1

w/JB & Tape

$29.69 Multitouch H HV Harn Asm, Push Cable Seal & Seat in Place Push Cable Seal 8.0000 sec 8.0000 sec $0.00 $0.07 3

w/JB & Tape & Seat in Place

$29.69 Operation H HV Harn Asm, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

w/JB & Tape

- - - Install Cover for HV Junction - - - - - -

Block

$28.80 P.-P. Part H HV Harn Asm, H HV JB Conn Cover, Molded H HV JB Conn 5.0000 sec 5.0000 sec - $0.04 1

w/JB & Tape Cover, Molded

$28.80 Tool H HV JB Conn Injection Molding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover, Molded 200-400 Ton

Design Profit ®

Page 31 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$28.80 Part H HV JB Conn H HV JB Conn Cover, Material H HV JB Conn 0.0000 sec 1.6120 sec $0.17 $0.01 1

Cover, Molded Cover, Material

- - - Raw Material Req 0.119 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 70mm L x 49mm W x - - - - - -

75mm H

$29.69 Fastening H HV Harn Asm, Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 2

w/JB & Tape

$29.69 Operation H HV Harn Asm, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

w/JB & Tape

$50.58 P.-P. Part H HV Harn Asm, H HV JB Cover Rear, Molded H HV JB Cover 8.0000 sec 8.0000 sec - $0.07 1

w/JB & Tape Rear, Molded

$50.58 Tool H HV JB Cover Inj Molding Machine 400-800 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Rear, Molded

$50.58 Part H HV JB Cover H HV JB Cover Rear, Material H HV JB Cover 0.0000 sec 1.7360 sec $0.25 $0.02 1

Rear, Molded Rear, Material

- - - Raw Material Req 0.140 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 146mm L x 114mm W x - - - - - -

53mm H

$29.69 Operation H HV Harn Asm, Turn Asm Over 3.0000 sec 3.0000 sec $0.00 $0.02 1

w/JB & Tape

$29.69 P.-P. Part H HV Harn Asm, H HV JB Cover Front, Molded H HV JB Cover 8.0000 sec 8.0000 sec - $0.07 1

w/JB & Tape Front, Molded

$29.69 Tool H HV JB Cover Injection Molding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Front, Molded 200-400 Ton

$29.69 Part H HV JB Cover H HV JB Cover Front, Material H HV JB Cover 0.0000 sec 1.6740 sec $0.11 $0.01 1

Front, Molded Front, Material

- - - Raw Material Req 0.064 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 100mm L x 94mm W x - - - - - -

46mm H

$29.69 Fastening H HV Harn Asm, Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 5

w/JB & Tape

- - - Install HV Harn to Trans Bracket - - - - - -

Mate

$29.69 Multitouch H Cable Asm, H Manip HV Harness H Manip HV 11.0000 sec 11.0000 sec $0.00 $0.09 1

HV, Covered Harness

Design Profit ®

Page 32 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$35.51 Subassembly H Cable Asm, H Bracket Clip Asm, HV Cable, H Bracket Clip 8.0000 sec 8.0000 sec - $0.07 1

HV, Covered Taped On Asm, HV Cable, 

Taped On

$35.51 Tool H Bracket Clip Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, HV Cable, 

Taped On

$28.80 P.-P. Part H Bracket Clip H Bracket Clip ,HV Cable, Taped H Bracket 3.0000 sec 3.0000 sec - $0.03 1

Asm, HV Cable, On Clip ,HV Cable, 

Taped On Taped On

$28.80 Tool H Bracket Injection Molding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Clip ,HV Cable, 200-400 Ton

Taped On

$28.80 Part H Bracket H Bracket Clip ,HV Cable, Taped H Bracket 0.0000 sec 1.5550 sec $0.07 $0.01 1

Clip ,HV Cable, On, Material Clip ,HV Cable, 

Taped On Taped On, 

Material

- - - Raw Material Req 0.041 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 102mm L x 52mm W x - - - - - -

19mm H

$35.51 Operation Operation H Bracket Clip H Bracket Clip Load Part Load Part 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec $0.00 $0.03 1

Asm, HV Cable, 

Taped On

$10.75 P.-P. Part H Bracket Clip H Crush Sleeve, Bracket Clip, HV H Crush Sleeve, 5.0000 sec 5.0000 sec - $0.05 1

Asm, HV Cable, Cable Bracket Clip, HV 

Taped On Cable

$10.75 Tool H Crush Sleeve, Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Bracket Clip, HV DRY

Cable

$15.50 P.-P. Part H Crush Sleeve, H Crush Sleeve, Bracket Clip, HV H Crush Sleeve, 3.0000 sec 3.0000 sec - $0.01 1

Bracket Clip, HV Cable, Stamped Bracket Clip, HV 

Cable Cable, Stamped

$15.50 Tool H Crush Sleeve, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Bracket Clip, HV 

Cable, Stamped

$15.50 Part H Crush Sleeve, H Crush Sleeve, Bracket Clip, HV H Crush Sleeve, 0.0000 sec 0.6000 sec $0.01 $0.00 1

Bracket Clip, HV Cable, Stamped Bracket Clip, HV 

Cable, Stamped Cable, Material

- - - Blank weight 0.011 lbs - - - - - -

- - - Press Size 25 Ton & Progressive - - - - - -

Design Profit ®

Page 33 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Part Size after stamping 16 L by - - - - - -

9.5 W by 9.5 H)mm

$10.75 Operation H Crush Sleeve, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Bracket Clip, HV 

Cable

$10.75 Operation H Crush Sleeve, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 1

Bracket Clip, HV 

Cable

$10.75 Operation H Crush Sleeve, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Bracket Clip, HV 

Cable

$35.51 Fastening H Bracket Clip Press Together 3.0000 sec 3.0000 sec $0.00 $0.03 1

Asm, HV Cable, 

Taped On

$35.51 Operation H Bracket Clip Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Asm, HV Cable, 

Taped On

$29.69 Part H Cable Asm, H Black Duct Tape, 1" x 20.5" H Black Duct 5.0000 sec 5.0000 sec $0.03 $0.04 1

HV, Covered Long Tape, 1" Wide

$29.69 Fastening H Cable Asm, Apply Tape 5.1249 sec 5.1249 sec $0.00 $0.04 1

HV, Covered

$29.69 Operation Operation H Cable Asm, H Cable Asm, 18" Move 18" Move 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec $0.00 $0.02 1

HV, Covered

- - - Install HV Harn Cover at AC - - - - - -

Comp Conn End

$29.69 Multitouch H Cable Asm, H Manip HV Harness H Manip HV 11.0000 sec 11.0000 sec $0.00 $0.09 1

HV, Covered Harness

$28.80 P.-P. Part H Cable Asm, H HV Harness Lower Cover, #4, H HV Harness 7.0000 sec 7.0000 sec - $0.06 1

HV, Covered Molded Lower Cover, #4, 

Molded

$28.80 Tool H HV Harness Injection Molding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Lower Cover, #4, 200-400 Ton

Molded

$28.80 Part H HV Harness H HV Harness Lower Cover, #4, H HV Harness 0.0000 sec 1.5530 sec $0.20 $0.01 1

Lower Cover, #4, Material Lower Cover, #4, 

Molded Material

- - - Raw Material Req 0.112 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 320mm L x 51mm W x - - - - - -

50mm H

Design Profit ®

Page 34 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$29.69 Fastening H Cable Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 3

HV, Covered

$29.69 Part H Cable Asm, H Orange Tape, 5/8" x 10" Long H Orange Tape, 5.0000 sec 5.0000 sec $0.01 $0.04 2

HV, Covered 5/8" Wide

$29.69 Fastening H Cable Asm, Apply Tape 2.4999 sec 2.4999 sec $0.00 $0.02 2

HV, Covered

$29.69 Fastening H Cable Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 3

HV, Covered

$28.80 P.-P. Part H Cable Asm, H HV Harness Upper Cover, #4, H HV Harness 7.0000 sec 7.0000 sec - $0.06 1

HV, Covered Molded Upper Cover, #4, 

Molded

$28.80 Tool H HV Harness Injection Molding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Upper Cover, #4, 200-400 Ton

Molded

$28.80 Part H HV Harness H HV Harness Upper Cover, #4, H HV Harness 0.0000 sec 1.3440 sec $0.06 $0.01 1

Upper Cover, #4, Material Upper Cover, #4, 

Molded Material

- - - Raw Material Req 0.033 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 291mm L x 43mm W x - - - - - -

32mm H

$29.69 Fastening H Cable Asm, Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 3

HV, Covered

$29.69 Operation H Cable Asm, 18" Move 2.0000 sec 2.0000 sec $0.00 $0.02 1

HV, Covered

- - - Install HV Harn Cover at Main - - - - - -

Power Lead

$29.69 Multitouch H Cable Asm, H Manip HV Harness H Manip HV 11.0000 sec 11.0000 sec $0.00 $0.09 1

HV, Covered Harness

$35.51 Subassembly H Cable Asm, H HV Harness Lower Cover Asm, H HV Harness 7.0000 sec 7.0000 sec - $0.06 1

HV, Covered #5 Lower Cover 

Asm, #5

$35.51 Tool H HV Harness Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Lower Cover 

Asm, #5

$50.58 P.-P. Part H HV Harness H HV Harness Lower Cover Asm, H HV Harness 3.0000 sec 3.0000 sec - $0.03 1

Lower Cover #5 Lower Cover 

Asm, #5 Asm, #5, Molded

$50.58 Tool H HV Harness Inj Molding Machine 400-800 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Lower Cover 

Asm, #5

Design Profit ®

Page 35 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$50.58 Part H HV Harness H HV Harness Lower Cover Asm, H HV Harness 0.0000 sec 1.8160 sec $0.18 $0.03 1

Lower Cover #5, Material Lower Cover 

Asm, #5 Asm, #5, Material

- - - Raw Material Req 0.102 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 204mm L x 114mm W x - - - - - -

36mm H

$35.51 Operation H HV Harness Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Lower Cover 

Asm, #5

$10.75 P.-P. Part H HV Harness H Crush Sleeve Large, Bracket H Crush Sleeve 5.0000 sec 5.0000 sec - $0.05 1

Lower Cover Clip, HV Cable Large, Bracket 

Asm, #5 Clip, HV Cable

$10.75 Tool H Crush Sleeve Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Large, Bracket DRY

Clip, HV Cable

$15.50 P.-P. Part H Crush Sleeve H Crush Sleeve Large, Bracket H Crush Sleeve 3.0000 sec 3.0000 sec - $0.01 1

Large, Bracket Clip, HV Cable, Mold Large, Bracket 

Clip, HV Cable Clip, HV Cable, 

Mold

$15.50 Tool H Crush Sleeve H Crush Sleeve Stamping Press 0-60 Ton Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 1

Large, Bracket 

Clip, HV Cable, 

Mold

$15.50 Part H Crush Sleeve H Crush Sleeve Large, Bracket H Crush Sleeve 0.0000 sec 0.6000 sec $0.01 $0.00 1

Large, Bracket Clip, HV Cable, Mate Large, Bracket 

Clip, HV Cable, Clip, HV Cable, 

Mold Mate

- - - Blank weight 0.015 lbs - - - - - -

- - - Press Size 25 Ton & Progressive - - - - - -

- - - Part Size after stamping (20 L x - - - - - -

15 W x 11 H)mm

$10.75 Operation H Crush Sleeve Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Large, Bracket 

Clip, HV Cable

$10.75 Operation H Crush Sleeve Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 1

Large, Bracket 

Clip, HV Cable

$10.75 Operation H Crush Sleeve Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Large, Bracket 

Clip, HV Cable

Design Profit ®

Page 36 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$35.51 Fastening H HV Harness Press Together 3.0000 sec 3.0000 sec $0.00 $0.03 1

Lower Cover 

Asm, #5

$35.51 Operation H HV Harness Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Lower Cover 

Asm, #5

$29.69 Fastening H Cable Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 2

HV, Covered

$29.69 Part H Cable Asm, H Wrap Tie, HV Harness Cover H Wrap Tie, HV 12.0000 sec 12.0000 sec $0.01 $0.10 2

HV, Covered Harness Cover

$29.69 Fastening H Cable Asm, Zip Tie 3.0000 sec 3.0000 sec $0.00 $0.02 2

HV, Covered

$29.69 Tool H Cable Asm, Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.02 1

HV, Covered

$29.69 Fastening H Cable Asm, Trim to Length 1.0000 sec 1.0000 sec $0.00 $0.01 2

HV, Covered

$50.58 P.-P. Part H Cable Asm, H HV Harness Upper Cover Asm, H HV Harness 7.0000 sec 7.0000 sec - $0.06 1

HV, Covered #5, Molded Upper Cover 

Asm, #5, Molded

$50.58 Tool H HV Harness Inj Molding Machine 400-800 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Upper Cover 

Asm, #5, Molded

$50.58 Part H HV Harness H HV Harness Upper Cover Asm, H HV Harness 0.0000 sec 1.5410 sec $0.19 $0.02 1

Upper Cover #5, Material Upper Cover 

Asm, #5, Molded Asm, #5, Material

- - - Raw Material Req 0.111 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 232mm L x 125mm W x - - - - - -

38mm H

$29.69 Fastening H Cable Asm, Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 3

HV, Covered

$29.69 Part H Cable Asm, H Black Duct Tape, 3/4" x 14" H Black Duct 5.0000 sec 5.0000 sec $0.02 $0.04 1

HV, Covered Long Tape, 3/4" Wide

$29.69 Fastening H Cable Asm, Apply Tape 3.5010 sec 3.5010 sec $0.00 $0.03 1

HV, Covered

$29.69 Operation H Cable Asm, 18" Move 2.0000 sec 2.0000 sec $0.00 $0.02 1

HV, Covered

- - - Install Small Central HV Harn - - - - - -

Cover

$29.69 Multitouch H Cable Asm, H Manip HV Harness H Manip HV 11.0000 sec 11.0000 sec $0.00 $0.09 1

HV, Covered Harness

Design Profit ®

Page 37 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$35.51 Subassembly H Cable Asm, H HV Harn Lower Cover Asm, #6 H HV Harn Lower 7.0000 sec 7.0000 sec - $0.06 1

HV, Covered Cover Asm, #6

$35.51 Tool H HV Harn Lower Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Asm, #6

$50.58 P.-P. Part H HV Harn Lower H HV Harn Lower Cover Asm, #6, H HV Harn Lower 3.0000 sec 3.0000 sec - $0.03 1

Cover Asm, #6 Molded Cover Asm, #6, 

Molded

$50.58 Tool H HV Harn Lower Inj Molding Machine 400-800 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Asm, #6, 

Molded

$50.58 Part H HV Harn Lower H HV Harn Lower Cover Asm, #6, H HV Harn Lower 0.0000 sec 1.5740 sec $0.21 $0.02 1

Cover Asm, #6, Material Cover Asm, #6, 

Molded Material

- - - Raw Material Req 0.121 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 214mm L x 75mm W x - - - - - -

23mm H

$35.51 Operation H HV Harn Lower Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Cover Asm, #6

$10.75 P.-P. Part H HV Harn Lower H Crush Sleeve Large, Bracket H Crush Sleeve 5.0000 sec 5.0000 sec - $0.05 2

Cover Asm, #6 Clip, HV Cable Large, Bracket 

Clip, HV Cable

$10.75 Tool H Crush Sleeve Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 2

Large, Bracket DRY

Clip, HV Cable

$15.50 P.-P. Part H Crush Sleeve H Crush Sleeve Large, Bracket H Crush Sleeve 3.0000 sec 3.0000 sec - $0.01 2

Large, Bracket Clip, HV Cable, Mold Large, Bracket 

Clip, HV Cable Clip, HV Cable, 

Mold

$15.50 Tool H Crush Sleeve Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 2

Large, Bracket 

Clip, HV Cable, 

Mold

$15.50 Part H Crush Sleeve H Crush Sleeve Large, Bracket H Crush Sleeve 0.0000 sec 0.6000 sec $0.01 $0.00 2

Large, Bracket Clip, HV Cable, Mate Large, Bracket 

Clip, HV Cable, Clip, HV Cable, 

Mold Mate

- - - Blank weight 0.015 lbs - - - - - -

- - - Press Size 25 Ton & Progressive - - - - - -

- - - Part Size after stamping (20 L x - - - - - -

15 W x 11 H)mm

Design Profit ®

Page 38 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$10.75 Operation H Crush Sleeve Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 2

Large, Bracket 

Clip, HV Cable

$10.75 Operation H Crush Sleeve Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 2

Large, Bracket 

Clip, HV Cable

$10.75 Operation H Crush Sleeve Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 2

Large, Bracket 

Clip, HV Cable

$35.51 Fastening H HV Harn Lower Press Together 3.0000 sec 3.0000 sec $0.00 $0.03 2

Cover Asm, #6

$35.51 Operation H HV Harn Lower Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Cover Asm, #6

$29.69 Fastening H Cable Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 4

HV, Covered

$50.58 P.-P. Part H Cable Asm, H HV Harn Upper Cover Asm, #6, H HV Harn Upper 7.0000 sec 7.0000 sec - $0.06 1

HV, Covered Molded Cover Asm, #6, 

Molded

$50.58 Tool H HV Harn Upper Inj Molding Machine 400-800 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Asm, #6, 

Molded

$50.58 Part H HV Harn Upper H HV Harn Upper H HV Harn Upper Cover Asm, #6, H HV Harn Upper Cover Asm, #6, H HV Harn Upper H HV Harn Upper 0.0000 sec 0.0000 sec 1.5700 sec 1.5700 sec $0.12 $0.02 1

Cover Asm, #6, Molded Cover Asm, #6, 

Molded Material

- - - Raw Material Req 0.070 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 214L x 53mm W x - - - - - -

14mm H

$29.69 Fastening H Cable Asm, Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 3

HV, Covered

$29.69 Operation H Cable Asm, 18" Move 2.0000 sec 2.0000 sec $0.00 $0.02 1

HV, Covered

- - - Install Large Central HV Harn - - - - - -

Cover

$29.69 Multitouch H Cable Asm, H Manip HV Harness H Manip HV 11.0000 sec 11.0000 sec $0.00 $0.09 1

HV, Covered Harness

$35.51 Subassembly H Cable Asm, H HV Harn Lower Cover Asm, #7 H HV Harn Lower 8.0000 sec 8.0000 sec - $0.07 1

HV, Covered Cover Asm, #7

$35.51 Tool H HV Harn Lower Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Asm, #7

Design Profit ®

Page 39 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$50.58 P.-P. Part H HV Harn Lower H HV Harn Lower Cover Asm, #7, H HV Harn Lower 3.0000 sec 3.0000 sec - $0.03 1

Cover Asm, #7 Molded Cover Asm, #7, 

Molded

$50.58 Tool H HV Harn Lower Inj Molding Machine 800-1500 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Asm, #7, Ton

Molded

$50.58 Part H HV Harn Lower H HV Harn Lower Cover Asm, #7, H HV Harn Lower 0.0000 sec 2.9950 sec $0.77 $0.04 1

Cover Asm, #7, Material Cover Asm, #7, 

Molded Material

- - - Raw Material Req 0.440 lbs from - - - - - -

Cost Sheet

- - - 6 Cavity Mold - - - - - -

- - - Box Size 662mm L x 175mm W x - - - - - -

28mm H

$35.51 Operation H HV Harn Lower Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Cover Asm, #7

$10.75 P.-P. Part H HV Harn Lower H Crush Sleeve Large, Bracket H Crush Sleeve 5.0000 sec 5.0000 sec - $0.05 3

Cover Asm, #7 Clip, HV Cable Large, Bracket 

Clip, HV Cable

$10.75 Tool H Crush Sleeve Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 3

Large, Bracket DRY

Clip, HV Cable

$15.50 P.-P. Part H Crush Sleeve H Crush Sleeve Large, Bracket H Crush Sleeve 3.0000 sec 3.0000 sec - $0.01 3

Large, Bracket Clip, HV Cable, Mold Large, Bracket 

Clip, HV Cable Clip, HV Cable, 

Mold

$15.50 Tool H Crush Sleeve Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 3

Large, Bracket 

Clip, HV Cable, 

Mold

$15.50 Part H Crush Sleeve H Crush Sleeve Large, Bracket H Crush Sleeve 0.0000 sec 0.6000 sec $0.01 $0.00 3

Large, Bracket Clip, HV Cable, Mate Large, Bracket 

Clip, HV Cable, Clip, HV Cable, 

Mold Mate

- - - Blank weight 0.015 lbs - - - - - -

- - - Press Size 25 Ton & Progressive - - - - - -

- - - Part Size after stamping (20 L x - - - - - -

15 W x 11 H)mm

$10.75 Operation H Crush Sleeve Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 3

Large, Bracket 

Clip, HV Cable

Design Profit ®

Page 40 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$10.75 Operation H Crush Sleeve Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 3

Large, Bracket 

Clip, HV Cable

$10.75 Operation H Crush Sleeve Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 3

Large, Bracket 

Clip, HV Cable

$35.51 Fastening H HV Harn Lower Press Together 3.0000 sec 3.0000 sec $0.00 $0.03 3

Cover Asm, #7

$35.51 Operation H HV Harn Lower Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Cover Asm, #7

$29.69 Fastening H Cable Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 4

HV, Covered

$29.69 Operation H Cable Asm, 18" Move 2.0000 sec 2.0000 sec $0.00 $0.02 1

HV, Covered

$29.69 Fastening H Cable Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 4

HV, Covered

$50.58 P.-P. Part H Cable Asm, H HV Harn Upper Cover Asm, #7, H HV Harn Upper 8.0000 sec 8.0000 sec - $0.07 1

HV, Covered Molded Cover Asm, #7, 

Molded

$50.58 Tool H HV Harn Upper Inj Molding Machine 800-1500 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Asm, #7, Ton

Molded

$50.58 Part H HV Harn Upper H HV Harn Upper Cover Asm, #7, H HV Harn Upper 0.0000 sec 2.8660 sec $0.42 $0.04 1

Cover Asm, #7, Molded Cover Asm, #7, 

Molded Material

- - - Raw Material Req 0.238 lbs from - - - - - -

Cost Sheet

- - - 6 Cavity Mold - - - - - -

- - - Box Size 662mm L x 180mm W x - - - - - -

20mm H

$29.69 Fastening H Cable Asm, Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 7

HV, Covered

$29.69 Part H Cable Asm, H Black Duct Tape, 3/4" x 14" H Black Duct 5.0000 sec 5.0000 sec $0.02 $0.04 1

HV, Covered Long Tape, 3/4" Wide

$29.69 Fastening H Cable Asm, Apply Tape 3.2490 sec 3.2490 sec $0.00 $0.03 1

HV, Covered

- - - Install HV Harn Cover at HV BEC - - - - - -

End

$29.69 Multitouch H Cable Asm, H Manip HV Harness H Manip HV 11.0000 sec 11.0000 sec $0.00 $0.09 1

High Voltage Harness

Design Profit ®
Page 41 of 53

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$50.58 P.-P. Part H Cable Asm, H HV Harness Cover, #3, Molded H HV Harness 7.0000 sec 7.0000 sec - $0.06 1

High Voltage Clamshell Cover, #3, 

Molded Clamshell

$50.58 Tool H HV Harness Inj Molding Machine 400-800 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover, #3, 

Molded Clamshell

$50.58 Part H HV Harness H HV Harness Cover, #3, H HV Harness 0.0000 sec 1.9520 sec $0.29 $0.03 1

Cover, #3, Material Cover, #3, 

Molded Clamshell Material

- - - Raw Material Req 0.164 lbs from - - - - - -

Cost Sheet

- - - 6 Cavity Mold - - - - - -

- - - Box Size 225mm L x 120mm W x - - - - - -

20mm H

$29.69 Fastening H Cable Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 4

High Voltage

$29.69 Multitouch H Cable Asm, H Manipulate Clamshell Cover H Manipulate 8.0000 sec 8.0000 sec $0.00 $0.07 1

High Voltage Clamshell Cover

$29.69 Fastening H Cable Asm, Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 2

High Voltage

$29.69 Part H Cable Asm, H Black Duct Tape, 3/4" x 10.25" H Black Duct 5.0000 sec 5.0000 sec $0.01 $0.04 1

High Voltage Long Tape, 3/4" Wide

$29.69 Fastening H Cable Asm, Apply Tape 2.5620 sec 2.5620 sec $0.00 $0.02 1

High Voltage

$29.69 Operation H Cable Asm, 18" Move 2.0000 sec 2.0000 sec $0.00 $0.02 1

High Voltage

- - - Mate DC-AC Harn to HV Harn - - - - - -

with Covers

$29.69 Multitouch H Cable Asm, H Manip HV Harness H Manip HV 11.0000 sec 11.0000 sec $0.00 $0.09 1

High Voltage Harness

$29.69 Subassembly H Cable Asm, H HV Harn Lower Cover Asm, #1 H HV Harn Lower 8.0000 sec 8.0000 sec - $0.07 1

High Voltage Cover Asm, #1

$29.69 Tool H HV Harn Lower First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Asm, #1

$50.58 P.-P. Part H HV Harn Lower H HV Harn Lower Cover, #1, H HV Harn Lower 3.0000 sec 3.0000 sec - $0.02 1

Cover Asm, #1 Molded Cover, #1, 

Molded

$50.58 Tool H HV Harn Lower Inj Molding Machine 400-800 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover, #1, 

Molded

Design Profit ®
Page 42 of 53

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$50.58 Part H HV Harn Lower H HV Harn Lower Cover, #1, H HV Harn Lower 0.0000 sec 2.0340 sec $0.43 $0.03 1

Cover, #1, Material Cover, #1, 

Molded Material

- - - Raw Material Req 0.243 lbs from - - - - - -

Cost Sheet

- - - 6 Cavity Mold - - - - - -

- - - Box Size 432mm L x 82mm W x - - - - - -

27mm H

$29.69 Part H HV Harn Lower H Push Pin, Harness Cover H Push Pin, 5.0000 sec 5.0000 sec $0.03 $0.04 2

Cover Asm, #1 Harness Cover

$29.69 Fastening H HV Harn Lower Press in Xmass Clip 3.0000 sec 3.0000 sec $0.00 $0.02 2

Cover Asm, #1

$29.69 Fastening H Cable Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 4

High Voltage

$29.69 Subassembly H Cable Asm, H DC-AC to Console Harness H DC-AC to 11.0000 sec 11.0000 sec - $0.09 1

High Voltage Asm Console Harness 

Asm

$29.69 Tool H DC-AC to First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Console Harness 

Asm

$29.69 Subassembly H DC-AC to H DC-AC to Console Harness H DC-AC to 4.0000 sec 4.0000 sec $2.10 $0.03 1

Console Harness Console Harness

Asm

$29.69 Tool H DC-AC to First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Console Harness

- - - 160" 18 Gauge Wire: $0.267 - - - - - -

- - - 160" 16 Gauge Wire: $0.400 - - - - - -

- - - 10 x 1.5mm Unsealed Conn: - - - - - -

$0.14

- - - 6 x 1.5mm Unsealed Conn: - - - - - -

$0.08

- - - 8 - 1.5mm Female Spade Terms: - - - - - -

$0.12

- - - 2 - TPAs: $0.075 - - - - - -

- - - 65" - 1/4" Orange Convolute: - - - - - -

$0.38

- - - 235" - 3/4" Orange Tape: $0.196 - - - - - -

- - - 37" - 3/4" Black Duct Tape: - - - - - -

$0.05

- - - 24" - 3/4" Black Fabric Tape: - - - - - -

$0.03

Design Profit ®

Page 43 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - 1 - Edge Biter Clip $0.10 - - - - - -

- - - 1 std, 2 mod - Tape on Clips - - - - - -

$0.15

- - - 3 - Strap on Clips $0.12 - - - - - -

$16.39 P.-P. Part H DC-AC to H HV Harn Cover with Snap H HV Harn Cover 7.0000 sec 7.0000 sec - $0.06 1

Console Harness Conn, Molded with Snap Conn, 

Asm Molded

$16.39 Tool H HV Harn Cover Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

with Snap Conn, ton

Molded

$16.39 Part H HV Harn Cover H HV Harn Cover with Snap H HV Harn Cover 7.0000 sec 1.4540 sec $0.03 $0.01 1

with Snap Conn, Conn, Material with Snap Conn, 

Molded Material

- - - Raw Material Req 0.016 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 87mm L x 19mm W x - - - - - -

15mm H

$29.69 Fastening H DC-AC to Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 4

Console Harness 

Asm

$29.69 Part H DC-AC to H DC-AC to H Black Duct Tape, 3/4" x 6.5" H Black Duct Tape, 3/4" x 6.5" H Black Duct H Black Duct 5.0000 sec 5.0000 sec 5.0000 sec 5.0000 sec $0.01 $0.04 1

Console Harness Long Tape, 3/4" Wide

Asm

$29.69 Fastening H DC-AC to Apply Tape 1.6200 sec 1.6200 sec $0.00 $0.01 1

Console Harness 

Asm

$29.69 Part H DC-AC to H Black Duct Tape, 3/4" x 5" H Black Duct 5.0000 sec 5.0000 sec $0.01 $0.04 1

Console Harness Long Tape, 3/4" Wide

Asm

$29.69 Fastening H DC-AC to Apply Tape 1.2600 sec 1.2600 sec $0.00 $0.01 1

Console Harness 

Asm

$29.69 Fastening H Cable Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 1

High Voltage

$50.58 P.-P. Part H Cable Asm, H HV Harn Upper Cover, #1, H HV Harn Upper 7.0000 sec 7.0000 sec - $0.06 1

High Voltage Molded Cover, #1, 

Molded

$50.58 Tool H HV Harn Upper Inj Molding Machine 400-800 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover, #1, 

Molded

Design Profit ®

Page 44 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$50.58 Part H HV Harn Upper H HV Harn Upper Cover, #1, H HV Harn Upper 0.0000 sec 2.0050 sec $0.24 $0.03 1

Cover, #1, Material Cover, #1, 

Molded Material

- - - Raw Material Req 0.138 lbs from - - - - - -

Cost Sheet

- - - 6 Cavity Mold - - - - - -

- - - Box Size 450mm L x 78mm W x - - - - - -

15mm H

$29.69 Fastening H Cable Asm, Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 3

High Voltage

$29.69 Fastening H Cable Asm, Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 1

High Voltage

$29.69 Part H Cable Asm, H Black Duct Tape, 3/4" x 15" H Black Duct 5.0000 sec 5.0000 sec $0.02 $0.04 1

High Voltage Long Tape, 3/4" Wide

$29.69 Fastening H Cable Asm, Apply Tape 3.7500 sec 3.7500 sec $0.00 $0.03 1

High Voltage

$29.69 Part H Cable Asm, H Black Duct Tape, 3/4" x 53" H Black Duct 5.0000 sec 5.0000 sec $0.07 $0.04 1

High Voltage Long Tape, 3/4" Wide

$29.69 Fastening H Cable Asm, Apply Tape 13.2600 sec 13.2600 sec $0.00 $0.11 1

High Voltage

$29.69 Operation H Cable Asm, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

High Voltage

$29.69 Multitouch H Cable Asm, H Manip HV Harness H Manip HV 11.0000 sec 11.0000 sec $0.00 $0.09 1

High Voltage Harness

$28.80 P.-P. Part H Cable Asm, H HV Harn Lower Cover, #2, H HV Harn Lower 8.0000 sec 8.0000 sec - $0.07 1

High Voltage Molded Cover, #2, 

Molded

$28.80 Tool H HV Harn Lower Injection Molding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover, #2, 200-400 Ton

Molded

$28.80 Part H HV Harn Lower H HV Harn Lower Cover, #2, H HV Harn Lower 0.0000 sec 1.3790 sec $0.10 $0.01 1

Cover, #2, Material Cover, #2, 

Molded Material

- - - Raw Material Req 0.057 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 95mm L x 85mm W x - - - - - -

28mm H

$29.69 Fastening H Cable Asm, Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 5

High Voltage

Design Profit ®

Page 45 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$28.80 P.-P. Part H Cable Asm, H HV Harn Upper Cover, #2, H HV Harn Upper 7.0000 sec 7.0000 sec - $0.06 1

High Voltage Molded Cover, #2, 

Molded

$28.80 Tool H HV Harn Upper Injection Molding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover, #2, 200-400 Ton

Molded

$28.80 Part H HV Harn Upper H HV Harn Upper Cover, #2, H HV Harn Upper 0.0000 sec 0.9400 sec $0.04 $0.01 1

Cover, #2, Material Cover, #2, 

Molded Material

- - - Raw Material Req 0.024 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 85mm L x 68mm W x - - - - - -

13mm H

$29.69 Fastening H Cable Asm, Snap Together 1.0000 sec 1.0000 sec $0.00 $0.01 2

High Voltage

$29.69 Part H Cable Asm, H Black Duct Tape, 3/4" x 9.5" H Black Duct 5.0000 sec 5.0000 sec $0.01 $0.04 1

High Voltage Long Tape, 3/4" Wide

$29.69 Fastening H Cable Asm, Apply Tape 2.3700 sec 2.3700 sec $0.00 $0.02 1

High Voltage

$29.69 Part H Cable Asm, H Black Duct Tape, 3/4" x 15" H Black Duct 5.0000 sec 5.0000 sec $0.02 $0.04 1

High Voltage Long Tape, 3/4" Wide

$29.69 Fastening H Cable Asm, Apply Tape 3.7500 sec 3.7500 sec $0.00 $0.03 1

High Voltage

$29.69 Operation H Cable Asm, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

High Voltage

- - - Coil Harn at DC-DC Conn, Tape - - - - - -

for Shipping

$29.69 Multitouch H Cable Asm, H Coil Harness for Taping H Coil Harness 9.0000 sec 9.0000 sec $0.00 $0.07 1

High Voltage for Taping

$29.69 Part H Cable Asm, H Tear Tape, 3/8" Wide x 11" H Tear Tape, 3/8" 5.0000 sec 5.0000 sec $0.01 $0.04 1

High Voltage Long Wide

$29.69 Fastening H Cable Asm, Apply Tape 2.7600 sec 2.7600 sec $0.00 $0.02 1

High Voltage

- - - Coil Harn at Console Conn, Tape - - - - - -

for Shipping

$29.69 Multitouch H Cable Asm, H Coil Harness for Taping H Coil Harness 9.0000 sec 9.0000 sec $0.00 $0.07 1

High Voltage for Taping

$29.69 Part H Cable Asm, H Tear Tape, 3/8" Wide x 8.75" H Tear Tape, 3/8" 5.0000 sec 5.0000 sec $0.01 $0.04 1

High Voltage Long Wide

$29.69 Fastening H Cable Asm, Apply Tape 2.1900 sec 2.1900 sec $0.00 $0.02 1

High Voltage

Design Profit ®

Page 46 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Coil Harn at DC-AC Conv Conn, - - - - - -

Tape for Shipping

$29.69 Multitouch H Cable Asm, H Coil Harness for Taping H Coil Harness 9.0000 sec 9.0000 sec $0.00 $0.07 1

High Voltage for Taping

$29.69 Part H Cable Asm, H Tear Tape, 3/8" Wide x 18.5" H Tear Tape, 3/8" 5.0000 sec 5.0000 sec $0.01 $0.04 1

High Voltage Long Wide

$29.69 Fastening H Cable Asm, Apply Tape 4.6200 sec 4.6200 sec $0.00 $0.04 1

High Voltage

- - - Slide-press over dash bracket - - - - - -

$83.31 Fastening H Traction & HV Press Together 3.0000 sec 3.0000 sec $0.00 $0.07 1

Power 

Distribution Sub

$83.31 Fastening H Traction & HV Press in Xmass Clip 3.0000 sec 3.0000 sec $0.00 $0.07 2

Power 

Distribution Sub

$83.31 Part H Traction & HV H Nut, HV Cable Mounts H Nut, HV Cable 7.0000 sec 7.0000 sec $0.00 $0.16 2

Power Mounts

Distribution Sub

$83.31 Tool H Traction & HV Power Tool 4.0000 sec 4.0000 sec $0.00 $0.09 1

Power 

Distribution Sub

$83.31 Fastening Fastening H Traction & HV H Traction & HV Power Screw Power Screw 4.0000 sec 4.0000 sec 4.0000 sec 4.0000 sec $0.00 $0.09 2

Power 

Distribution Sub

- - - High Voltage cable routing Under - - - - - -

floor pan

$83.31 Multitouch H Traction & HV Cable High Volt battery to floor Cable High Volt 12.0000 sec 12.0000 sec $0.00 $0.28 1

Power pan floor pan to 

Distribution Sub Engine Comp-1-1

$83.31 Part H Traction & HV H Nut, HV Cable Mounts H Nut, HV Cable 7.0000 sec 7.0000 sec $0.00 $0.16 5

Power Mounts

Distribution Sub

$83.31 Tool H Traction & HV Power Tool 4.0000 sec 4.0000 sec $0.00 $0.09 1

Power 

Distribution Sub

$83.31 Fastening H Traction & HV Power Screw 4.0000 sec 4.0000 sec $0.00 $0.09 3

Power 

Distribution Sub

$83.31 Operation H Traction & HV CDI 1.0000 sec 1.0000 sec $0.00 $0.02 1

Power 

Distribution Sub

Design Profit ®

Page 47 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$83.31 Fastening H Traction & HV Power Screw 4.0000 sec 4.0000 sec $0.00 $0.09 2

Power 

Distribution Sub

- - - High Voltage cable routing thru - - - - - -

floor pan

$83.31 Multitouch H Traction & HV Cable High Volt battery to floor Cable High Volt 14.0000 sec 14.0000 sec $0.00 $0.32 1

Power pan battery to floor 

Distribution Sub pan-1

- - - Press fit into floor pan - - - - - -

$83.31 Fastening H Traction & HV Press Together 3.0000 sec 3.0000 sec $0.00 $0.07 1

Power 

Distribution Sub

- - - High Voltage cables Battery to - - - - - -

floor pan routing

$83.31 Multitouch H Traction & HV Cable High Volt battery to floor Cable High Volt 11.0000 sec 11.0000 sec $0.00 $0.25 1

Power pan battery to floor 

Distribution Sub pan

$83.31 Fastening H Traction & HV Press in Xmass Clip 3.0000 sec 3.0000 sec $0.00 $0.07 2

Power 

Distribution Sub

$83.31 Operation H Traction & HV 18" Move 2.0000 sec 2.0000 sec $0.00 $0.05 1

Power 

Distribution Sub

$83.31 Fastening H Traction & HV Press in Xmass Clip 3.0000 sec 3.0000 sec $0.00 $0.07 2

Power 

Distribution Sub

$83.31 Part H Traction & HV H Nut, HV Cable Mounts H Nut, HV Cable 7.0000 sec 7.0000 sec $0.00 $0.16 3

Power Mounts

Distribution Sub

$83.31 Tool H Traction & HV Power Tool 4.0000 sec 4.0000 sec $0.00 $0.09 1

Power 

Distribution Sub

$83.31 Fastening H Traction & HV Power Screw 4.0000 sec 4.0000 sec $0.00 $0.09 3

Power 

Distribution Sub

$50.58 P.-P. Part H Traction & HV H Cover Cable Pass Thru H Cover Cable 5.0000 sec 5.0000 sec - $0.12 1

Power Pass Thru

Distribution Sub

$50.58 Tool H Cover Cable Inj Molding Machine 400-800 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Pass Thru

$50.58 Part H Cover Cable H Cover Cable Pass Thru, H Cover Cable 0.0000 sec 2.6130 sec $0.33 $0.04 1

Pass Thru Material Pass Thru, 

Material

Design Profit ®
Page 48 of 53

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Raw Material Req 0.192 lbs from - - - - - -

Cost Sheet

- - - 6 Cavity Mold - - - - - -

- - - Box Size 195mm L x 130mm W x - - - - - -

30mm H

$83.31 Fastening H Traction & HV Snap Together 1.0000 sec 1.0000 sec $0.00 $0.02 1

Power 

Distribution Sub

- - - Transaxle Controller Power - - - - - -

Circuit

$83.31 Multitouch H Traction & HV Transaxle Controller Power Transaxle 14.0000 sec 14.0000 sec $0.00 $0.32 1

Power Circuit Controller Power 

Distribution Sub Circuit

$83.31 Fastening H Traction & HV Push in Electrical Connector 2.0000 sec 2.0000 sec $0.00 $0.05 1

Power 

Distribution Sub

$83.31 Operation H Traction & HV CDI 1.0000 sec 1.0000 sec $0.00 $0.02 1

Power 

Distribution Sub

$83.31 Fastening H Traction & HV Engage Connector Cam Lock 2.0000 sec 2.0000 sec $0.00 $0.05 1

Power 

Distribution Sub

$83.31 Part H Traction & HV H Stud Harness to Trans Bracket H Stud Harness 7.0000 sec 7.0000 sec $0.08 $0.16 1

Power to Trans Bracket

Distribution Sub

$83.31 Tool H Traction & HV Power Tool 4.0000 sec 4.0000 sec $0.00 $0.09 1

Power 

Distribution Sub

$83.31 Fastening H Traction & HV Power Screw 4.0000 sec 4.0000 sec $0.00 $0.09 1

Power 

Distribution Sub

- - - AC Compressor Power Cable - - - - - -

$83.31 Multitouch H Traction & HV AC Compressor Power Cable AC Compressor 7.0000 sec 7.0000 sec $0.00 $0.16 1

Power Power Cable

Distribution Sub

$83.31 Fastening H Traction & HV Press Together 3.0000 sec 3.0000 sec $0.00 $0.07 1

Power 

Distribution Sub

$83.31 Fastening H Traction & HV Push in Electrical Connector 2.0000 sec 2.0000 sec $0.00 $0.05 2

Power 

Distribution Sub

Design Profit ®

Page 49 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - High Volt Cables to Dist Box @ - - - - - -

Battery

$83.31 Multitouch H Traction & HV H High Voltage Cables to Battery H High Voltage 10.0000 sec 10.0000 sec $0.00 $0.23 1

Power Pack Cables to Battery 

Distribution Sub Pack

$83.31 Fastening H Traction & HV Press in Xmass Clip 3.0000 sec 3.0000 sec $0.00 $0.07 1

Power 

Distribution Sub

$83.31 Operation H Traction & HV CDI 1.0000 sec 1.0000 sec $0.00 $0.02 1

Power 

Distribution Sub

$83.31 Fastening H Traction & HV Push in Electrical Connector 2.0000 sec 2.0000 sec $0.00 $0.05 2

Power 

Distribution Sub

$83.31 Operation H Traction & HV CDI 1.0000 sec 1.0000 sec $0.00 $0.02 1

Power 

Distribution Sub

$83.31 Fastening H Traction & HV Engage Connector Cam Lock 2.0000 sec 2.0000 sec $0.00 $0.05 1

Power 

Distribution Sub

$83.31 Subassembly H Traction & HV H Battery Service Disconect Plug H Battery Service 6.0000 sec 6.0000 sec - $0.14 1

Power Disconect Plug

Distribution Sub

$83.31 Tool H Battery Service First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Disconect Plug

$29.69 P.-P. Part H Battery Service H Base, Battery Service Plug H Base, Battery 5.0000 sec 5.0000 sec - $0.12 1

Disconect Plug Service Plug

$29.69 Tool H Base, Battery Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Service Plug

- - - Crimp Insert Studs - - - - - -

$16.39 P.-P. Part H Base, Battery H Base, Battery Service H Base, Battery 3.0000 sec 3.0000 sec - $0.02 1

Service Plug Plug-Molding Service 

Plug-Molding

$16.39 Tool H Base, Battery Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

Service ton

Plug-Molding

$16.39 Part H Base, Battery H Base, Battery Service H Base, Battery 0.0000 sec 1.3380 sec $0.17 $0.01 1

Service Plug-Material Service 

Plug-Molding Plug-MoldingMaterial

- - - Raw Material Req 0.116 lbs from - - - - - -

Cost Sheet

Design Profit ®

Page 50 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - 10 Cavity Mold - - - - - -

- - - Box Size 83mm L x 52mm W x - - - - - -

61mm H

$29.69 Part H Base, Battery H Insert Stud, Battery Service H Insert Stud, 8.0000 sec 8.0000 sec $0.00 $0.07 2

Service Plug Plug Battery Service 

Plug

$29.69 Fastening H Base, Battery Set In Place 1.0000 sec 1.0000 sec $0.00 $0.01 2

Service Plug

$29.69 Fastening H Base, Battery Press Together 3.0000 sec 3.0000 sec $0.00 $0.02 2

Service Plug

- - - Insert Terminals - - - - - -

$10.75 P.-P. Part H Battery Service H Terminal, Battery Service Plug H Terminal, 6.0000 sec 6.0000 sec - $0.14 2

Disconect Plug Battery Service 

Plug

$10.75 Tool H Terminal, Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 2

Battery Service DRY

Plug

$15.50 P.-P. Part H Terminal, H Terminal, Battery Service H Terminal, 3.0000 sec 3.0000 sec - $0.01 2

Battery Service Plug-Stamping Battery Service 

Plug Plug-Stamping

$15.50 Tool H Terminal, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 2

Battery Service 

Plug-Stamping

$15.50 Part H Terminal, H Terminal, Battery Service Plug- H Terminal, 0.0000 sec 0.6000 sec $0.52 $0.00 2

Battery Service Material Battery Service 

Plug-Stamping Plug-Material

- - - Blank weight 0.114 lbs - - - - - -

- - - Press Size 25 Ton & Progressive - - - - - -

- - - Part Size after stamping 47 L by - - - - - -

40 W by 24 H)mm

- - - Batch Type Washer - - - - - -

- - - 5-10 min cycle time - - - - - -

- - - Basket Size 15.75x18.50x25.50 - - - - - -

inches x 2

$10.75 Operation H Terminal, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 2

Battery Service 

Plug

$10.75 Operation H Terminal, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 2

Battery Service 

Plug

Design Profit ®

Page 51 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$10.75 Operation H Terminal, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 2

Battery Service 

Plug

$83.31 Fastening H Battery Service Push In Place 2.0000 sec 2.0000 sec $0.00 $0.05 2

Disconect Plug

$83.31 Part H Battery Service H Fuse, Service Plug H Fuse, Service 6.0000 sec 6.0000 sec $0.00 $0.14 1

Disconect Plug Plug

$83.31 Fastening H Battery Service Set In Place 1.0000 sec 1.0000 sec $0.00 $0.02 1

Disconect Plug

$83.31 Part H Battery Service H Screw, Battery Service Plug H Screw, Battery 6.0000 sec 6.0000 sec $0.00 $0.14 1

Disconect Plug Service Plug

$83.31 Part H Battery Service H Washer, Battery Service Plug H Washer, 2.0000 sec 2.0000 sec $0.00 $0.05 1

Disconect Plug Battery Service 

Plug

$83.31 Tool H Battery Service 2 Spindle Nut Runner 6.0000 sec 6.0000 sec $0.00 $0.14 1

Disconect Plug

$83.31 Fastening H Battery Service Power Screw 4.0000 sec 4.0000 sec $0.00 $0.09 1

Disconect Plug

- - - Snap on Cover & Latch - - - - - -

$16.39 P.-P. Part H Battery Service H Cover, Battery Service Plug H Cover, Battery 6.0000 sec 6.0000 sec - $0.14 1

Disconect Plug Service Plug

$16.39 Tool H Cover, Battery H Cover, Battery Injection Molding Machine 55-150 Injection Molding Machine 55-150 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 1

Service Plug ton

$16.39 Part H Cover, Battery H Cover, Battery Service H Cover, Battery 0.0000 sec 1.4980 sec $0.02 $0.01 1

Service Plug Plug-Material Service 

Plug-Material

- - - Raw Material Req 0.026 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 90mm L x 46mm W x - - - - - -

12mm H

$16.39 P.-P. Part H Battery Service H Latch, Battery Service Plug H Latch, Battery 6.0000 sec 6.0000 sec - $0.14 1

Disconect Plug Service Plug

$16.39 Tool H Latch, Battery Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

Service Plug ton

$16.39 Part H Latch, Battery H Latch, Battery Service H Latch, Battery 0.0000 sec 8.1730 sec $0.10 $0.04 1

Service Plug Plug-Material Service 

Plug-Material

- - - Raw Material Req 0.061 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

Design Profit ®

Page 52 of 53
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Box Size 108mm L x 53mm W x - - - - - -

36mm H

$83.31 Fastening H Battery Service Snap Together 1.0000 sec 1.0000 sec $0.00 $0.02 2

Disconect Plug

- - - Apply Label - - - - - -

$83.31 Part H Battery Service H Label, Battery Service Plug H Label, Battery 5.0000 sec 5.0000 sec $0.10 $0.12 1

Disconect Plug Service Plug

$83.31 Fastening H Battery Service Apply Label 3.0000 sec 3.0000 sec $0.00 $0.07 1

Disconect Plug

$83.31 Fastening H Traction & HV Push in Electrical Connector 2.0000 sec 2.0000 sec $0.00 $0.05 1

Power 

Distribution Sub

$83.31 Fastening H Traction & HV Engage Connector Cam Lock 2.0000 sec 2.0000 sec $0.00 $0.05 1

Power 

Distribution Sub

Report Totals Count: 914

$20.90 940

Design Profit ®

Page 53 of 53
Copyright 2005© Munro & Associates, Inc.
Piece Cost 

(Total)

$0.00

-

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

Piece Cost 

(Total)

$0.00

$0.87

-

-

-

-

$0.00

$0.00

$0.01

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

Piece Cost 

(Total)

$0.00

-

$0.00

$0.07

-

-

-

$0.00

$0.29

$0.00

$0.00

$0.00

-

-

$0.00

-

Piece Cost 

(Total)

$0.00

-

$0.00

-

$0.00

-

$0.00

$0.18

-

-

-

-

$0.00

-

Piece Cost 

(Total)

$0.00

$0.16

-

-

-

-

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

-

Piece Cost 

(Total)

$0.00

-

$0.00

$0.05

-

-

-

-

$0.00

-

$0.00

-

$0.00

Piece Cost 

(Total)

$0.02

-

-

-

-

-

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$0.18

$0.00

$0.00

-

$0.00

-

$0.00

-

$0.00

-

$0.00

$254.29

$0.00

-

-

-

-

Piece Cost 

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

Piece Cost 

(Total)

-

-

-

$0.00

$0.66

-

-

-

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.18

-

-

-

$0.00

Piece Cost 

(Total)

$0.00

$0.01

$0.00

$0.00

$0.00

-

$0.00

-

$0.00

-

$0.00

$0.32

-

-

-

-

Piece Cost 

(Total)

$0.00

-

$0.00

$0.11

-

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.02

-

-

-

Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.06

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.03

-

-

-

Piece Cost 

(Total)

-

$0.00

$0.03

-

-

-

$0.00

-

$0.00

-

$0.00

-

$0.00

$0.32

-

-

Piece Cost 

(Total)

-

-

$0.00

-

$0.00

$0.11

-

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.02

Piece Cost 

(Total)

-

-

-

$0.00

$0.00

$0.00

$0.06

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.03

-

Piece Cost 

(Total)

-

-

-

$0.00

$0.03

-

-

-

$0.00

-

$0.00

-

$0.00

-

$0.00

$0.32

Piece Cost 

(Total)

-

-

-

-

$0.00

-

$0.00

$0.11

-

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

Piece Cost 

(Total)

$0.02

-

-

-

$0.00

$0.00

$0.00

$0.06

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

Piece Cost 

(Total)

-

$0.00

-

$0.00

$0.74

-

-

-

-

$0.00

-

$0.00

$0.07

-

-

-

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$0.00

$0.00

-

$0.00

$0.02

-

-

-

$0.00

$0.00

-

$0.00

$0.29

-

-

-

$0.00

$0.00

Piece Cost 

(Total)

$0.00

-

$0.00

$0.10

-

-

-

$0.00

$0.00

-

$0.00

$0.06

-

-

-

Piece Cost 

(Total)

$0.00

$0.00

$0.03

$0.00

$0.00

-

$0.00

-

$0.00

-

$0.00

$0.74

-

-

-

-

Piece Cost 

(Total)

$0.00

-

$0.00

$0.07

-

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.02

-

-

-

$0.00

Piece Cost 

(Total)

$0.00

-

$0.00

$0.29

-

-

-

$0.00

$0.00

$0.00

-

$0.00

$0.10

-

-

-

Piece Cost 

(Total)

$0.00

$0.00

-

$0.00

$0.06

-

-

-

$0.00

$0.00

$0.03

$0.00

$0.00

-

-

Piece Cost 

(Total)

$0.00

-

$0.00

$0.11

-

-

-

-

$0.00

$0.01

-

-

-

$0.00

$0.00

-

$0.00

-

Piece Cost 

(Total)

$0.00

$0.10

-

-

-

-

$0.00

-

$0.00

$0.12

-

-

-

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.03

-

Piece Cost 

(Total)

-

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

$0.00

$0.05

-

-

-

$0.00

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$0.00

-

$0.00

-

$0.00

-

$0.00

$0.09

-

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

-

Piece Cost 

(Total)

$0.00

-

$0.00

$0.09

-

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

-

-

$0.00

Piece Cost 

(Total)

$0.17

-

-

-

$0.00

$0.00

-

$0.00

$0.25

-

-

-

$0.00

-

$0.00

$0.11

-

-

-

$0.00

-

$0.00

Piece Cost 

(Total)

-

$0.00

-

$0.00

$0.07

-

-

-

$0.00

-

$0.00

-

$0.00

$0.01

-

-

Piece Cost 

(Total)

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.03

$0.00

$0.00

-

$0.00

-

$0.00

$0.20

-

-

-

Piece Cost 

(Total)

$0.00

$0.02

$0.00

$0.00

-

$0.00

$0.06

-

-

-

$0.00

$0.00

-

$0.00

-

$0.00

-

$0.00

Piece Cost 

(Total)

$0.18

-

-

-

$0.00

-

$0.00

-

$0.00

$0.01

-

-

-

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.02

$0.00

$0.00

$0.00

-

$0.00

$0.19

-

-

-

$0.00

$0.02

$0.00

$0.00

-

$0.00

Piece Cost 

(Total)

-

$0.00

-

$0.00

$0.21

-

-

-

$0.00

-

$0.00

-

$0.00

$0.01

-

-

-

Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.12

-

-

-

$0.00

$0.00

-

$0.00

-

$0.00

Piece Cost 

(Total)

-

$0.00

$0.77

-

-

-

$0.00

-

$0.00

-

$0.00

$0.02

-

-

-

$0.00

Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.42

-

-

-

$0.00

$0.02

$0.00

-

$0.00

Piece Cost 

(Total)

-

$0.00

$0.29

-

-

-

$0.00

$0.00

$0.00

$0.01

$0.00

$0.00

-

$0.00

-

$0.00

-

$0.00

Piece Cost 

(Total)

$0.43

-

-

-

$0.06

$0.00

$0.00

-

$0.00

$2.10

$0.00

-

-

-

-

-

-

-

-

-

-

Piece Cost 

(Total)

-

-

-

-

$0.00

$0.03

-

-

-

$0.00

$0.01

$0.00

$0.01

$0.00

$0.00

-

$0.00

Piece Cost 

(Total)

$0.24

-

-

-

$0.00

$0.00

$0.02

$0.00

$0.07

$0.00

$0.00

$0.00

-

$0.00

$0.10

-

-

-

$0.00

Piece Cost 

(Total)

-

$0.00

$0.04

-

-

-

$0.00

$0.01

$0.00

$0.02

$0.00

$0.00

-

$0.00

$0.01

$0.00

-

$0.00

$0.01

$0.00

Piece Cost 

(Total)

-

$0.00

$0.01

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$0.00

-

$0.00

-

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.33

Piece Cost 

(Total)

-

-

-

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.08

$0.00

$0.00

-

$0.00

$0.00

$0.00

Piece Cost 

(Total)

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

-

$0.00

-

-

$0.00

$0.17

-

Piece Cost 

(Total)

-

-

$0.00

$0.00

$0.00

-

-

$0.00

-

$0.00

$1.03

-

-

-

-

-

-

$0.00

$0.00

Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

$0.00

$0.02

-

-

-

-

$0.00

$0.10

-

-

Piece Cost 

(Total)

-

$0.00

-

$0.10

$0.00

$0.00

$0.00

$270.04

Indented Bill of Materials

H Traction & HV Power Distribution Sub

Level Symbol Name Number Qty Material Piece Cost Weight

H Bracket Asm, HV Cable to H Bracket $0.95 Trans Asm, HV 

Cable to 

Trans

1 H Bracket, HV Cable to H Bracket, HV 1 Steel - 1008 $0.88

Trans, Painted Cable to 

Trans, 

Painted

2 H Bracket, HV Cable to H Bracket, HV 1 Steel - 1008 $0.88

Trans, Washed Cable to 

Trans, 

Washed

3 H Bracket, HV Cable to H Bracket, HV 1 Steel - 1008 $0.88

Trans, Welded Cable to 

Trans, Welded

4 H Bracket, HV Cable to H Bracket, HV 1 Steel - 1008 $0.87

Trans, Engraved Cable to 

Trans, 

Engraved

5 H Bracket, HV Cable to H Bracket, HV 1 Steel - 1008

Trans, Stamped Cable to 

Trans, 

Stamped

6 H Bracket, HV Cable to Trans, H Bracket, HV 1 Steel - 1008

Material Cable to Trans, 

Material

4 H Weld Nut, Bracket HV Cable H Weld Nut, 1 Commodity $0.01

to Trans, 6mm Square Bracket HV Pricing

Cable to Trans, 

6mm Square

1 H Bracket Clip, HV Cable to H Bracket 1 Nylon 6/6 $0.07

Trans Clip, HV Cable 

to Trans

2 H Bracket Clip, HV Cable to H Bracket Clip, 1 Nylon 6/6 $0.07

Trans, Material HV Cable to 

Trans, Material

0 H Bolt Trans Cable Bracket H Bolt Trans 2 Commodity $0.15

Cable Bracket Pricing

Design Profit®

Page 1 of #
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Level Symbol Name Number Qty Material Piece Cost Weight

0 H Bracket Asm, HV Cable H Bracket 1 $0.41

Dash Asm, HV 

Cable Dash

1 H Bracket, HV Cable to Dash, H Bracket, HV 1 $0.34

Painted Cable to 

Dash, Painted

2 H Bracket, HV Cable to Dash, H Bracket, HV 1 $0.34

Washed Cable to 

Dash, Washed

3 H Bracket, HV Cable to Dash, H Bracket, HV 1 $0.34

Welded Cable to 

Dash, Welded

4 H Bracket Main, HV Cable to H Bracket 1 Steel - 1008 $0.18

Dash, Stamped Main, HV 

Cable to 

Dash, 

Stamped

5 H Bracket Main, HV Cable to H Bracket 1 Steel - 1008

Dash, Material Main, HV 

Cable to Dash, 

Material

4 H Bracket Stiffener, HV H Bracket 1 Steel - 1008 $0.16

Cable to Dash, Engraved Stiffener, HV 

Cable to 

Dash, 

Engraved

5 H Bracket Stiffener, HV H Bracket 1 Steel - 1008

Cable to Dash, Stamped Stiffener, HV 

Cable to 

Dash, 

Stamped

6 H Bracket Stiffener, HV Cable H Bracket 1 Steel - 1008

to Dash, Stamped Stiffener, HV 

Cable to Dash, 

Material

1 H Bushing Asm, Dash H Bushing 3 $0.02

Bracket Asm Asm, Dash 

Bracket Asm

2 H Bushing, Dash Bracket H Bushing, 1 SBR $0.02

Asm, Molded Dash Bracket 

Asm

Design Profit®
Page 

2 of#

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Level Symbol Name Number Qty Material Piece Cost

H Bushing, Dash Bracket Asm, H Bushing, 1 SBR $0.02

Material Dash Bracket 

Asm, Material

2 H Anti Crush Insert, Dash H Anti Crush 1 Steel - 1008 $0.01

Bracket Asm, Painted Insert, Dash 

Bracket Asm, 

Painted

3 H Anti Crush Insert, Dash H Anti Crush 1 Steel - 1008 $0.01

Bracket Asm, Washed Insert, Dash 

Bracket Asm, 

Washed

4 H Anti Crush Insert, Dash H Anti Crush 1 Steel - 1008 $0.01

Bracket Asm, Stamped Insert, Dash 

Bracket Asm, 

Stamped

5 H Anti Crush Insert, Dash H Anti Crush 1 Steel - 1008

Bracket Asm, Material Insert, Dash 

Bracket Asm, 

Material

0 H Bolt Bracket front of dash H Bolt Bracket 3 Commodity $0.06

front of dash Pricing

0 H Cable Asm, High Voltage H Cable 1 $266.38

Assembly

High Voltage

1 H Cable Asm, HV, Covered H Cable 1 $262.91

Assembly

High Voltage, 

Covered

2 H HV Harn Asm, w/JB & Tape H HV Harness 1 $260.54

Asm, with JB 

& Tape

3 H HV Harn Asm, w/ Tape & H HV Harn 1 $259.42

Connectors Asm, w/ Tape 

& Connectors

4 H HV Harn Asm, w/ Tape & H HV Harn 1 $254.29

Terminals Asm, w/ Tape 

& Terminals

4 H HV Cable Boot, Molded H HV Cable 1 EPDM $0.66

Boot, Molded

5 H HV Cable Boot, Material H HV Cable 1 EPDM

Boot, Material

Design Profit®
Page 

3 of#

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Level Symbol Name Number Qty Material Piece Cost

H HV Cable Boot Mount Asm H HV Cable 1 $0.18

Boot Mount 

Asm

5 H HV Boot Mount Bolt H HV Boot 3 Commodity 

Mount Bolt Pricing

5 H HV Cable Boot Mount, H HV Cable 1 PA66

Material Boot Mount, 

Material

4 H Wrap Tie, HV Harness H Wrap Tie, 1 Commodity $0.01

Mount HV Harness Pricing

Mount

4 H HV Medium Conn Asm, H HV Medium 1 $0.45

A/C Mod Conn Asm

5 H HV Medium Conn Body, H HV Medium 1 PA6T

Molded Conn Body, 

Molded

6 H HV Medium Conn Body, H HV Medium 1 PA6T

Material Conn Body, 

Material

5 H HV Medium Conn Shield H HV Medium 2 Stainless 

Conn Shield Steel

6 H HV Medium Conn Shield, H HV Medium 2 Stainless 

Stamped Conn Shield, Steel

Stamped

7

H HV Medium Conn Shield, H HV Medium 2 Stainless Steel

Material Conn Shield, 

Material

5 H HV Seal, Medium Conn, H HV Seal, 2 SBR

Molded Medium 

Conn, Molded

6 H HV Seal, Medium Conn, H HV Seal, 2 SBR

Material Medium Conn, 

Material

4 H HV TPA, Medium Conn H HV TPA, 2 Commodity $0.03

Medium Conn Pricing

4 H HV Cable Clamp Base, H HV Cable 1 PA66 $0.03

Med, Curved, Molded Clamp Base, 

Med, Curved, 

Molded

5 H HV Cable Clamp Base, Med, H HV Cable 1 PA66

Curved, Material Clamp Base, 

Med, Curved, 

Material

Design Profit®
Page 

4 of#

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Level Symbol Name Number Qty Material Piece Cost

H HV Cable Clamp Cover, H HV Cable 1 PA66 $0.03

Med, Curved, Molded Clamp Cover, 

Med, Curved, 

Molded

5 H HV Cable Clamp Cover, H HV Cable 1 PA66

Med, Curved, Material Clamp Cover, 

Med, Curved, 

Material

4 H HV Medium Conn Asm, H HV Medium 1 $0.45

DC-DC Conv Conn Asm

5 H HV Medium Conn Body, H HV Medium 1 PA6T

Molded Conn Body, 

Molded

6 H HV Medium Conn Body, H HV Medium 1 PA6T

Material Conn Body, 

Material

5 H HV Medium Conn Shield H HV Medium 2 Stainless 

Conn Shield Steel

6 H HV Medium Conn Shield, H HV Medium 2 Stainless 

Stamped Conn Shield, Steel

Stamped

7

H HV Medium Conn Shield, H HV Medium 2 Stainless Steel

Material Conn Shield, 

Material

5 H HV Seal, Medium Conn, H HV Seal, 2 SBR

Molded Medium 

Conn, Molded

6 H HV Seal, Medium Conn, H HV Seal, 2 SBR

Material Medium Conn, 

Material

4 H HV TPA, Medium Conn H HV TPA, 2 Commodity $0.03

Medium Conn Pricing

4 H HV Cable Clamp Base, H HV Cable 1 PA66 $0.03

Med, Straight, Molded Clamp Base, 

Med, Straight, 

Molded

5 H HV Cable Clamp Base, Med, H HV Cable 1 PA66

Straight, Material Clamp Base, 

Med, Straight, 

Material

Design Profit®
Page 

5 of#

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Level Symbol Name Number Qty Material Piece Cost

H HV Cable Clamp Cover, H HV Cable 1 PA66 $0.03

Med, Straight, Molded Clamp Cover, 

Med, Straight, 

Molded

5 H HV Cable Clamp Cover, H HV Cable 1 PA66

Med, Straight, Material Clamp Cover, 

Med, Straight, 

Material

4 H HV Medium Conn Asm, H HV Medium 1 $0.45

BEC Module Conn Asm

5 H HV Medium Conn Body, H HV Medium 1 PA6T

Molded Conn Body, 

Molded

6 H HV Medium Conn Body, H HV Medium 1 PA6T

Material Conn Body, 

Material

5 H HV Medium Conn Shield H HV Medium 2 Stainless 

Conn Shield Steel

6 H HV Medium Conn Shield, H HV Medium 2 Stainless 

Stamped Conn Shield, Steel

Stamped

7

H HV Medium Conn Shield, H HV Medium 2 Stainless Steel

Material Conn Shield, 

Material

5 H HV Seal, Medium Conn, H HV Seal, 2 SBR

Molded Medium 

Conn, Molded

6 H HV Seal, Medium Conn, H HV Seal, 2 SBR

Material Medium Conn, 

Material

4 H HV TPA, Medium Conn H HV TPA, 2 Commodity $0.03

Medium Conn Pricing

4 H HV Large Conn Asm, BEC H HV Large 1 $1.12

Module Conn Asm

5 H HV Large Conn Body, H HV Large 1 PA6T

Molded Conn Body, 

Molded

6 H HV Large Conn Body, H HV Large 1 PA6T

Material Conn Body, 

Material

5 H HV Large Conn Shield H HV Large 2 Stainless 

Conn Shield Steel
Design Profit

®

Page 6 of#

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Level Symbol Name Number Qty Material Piece Cost

6 H HV Large Conn Shield, H HV Large 1 Stainless 

Stamped Conn Shield, Steel

Stamped

7

H HV Large Conn Shield, H HV Large 1 Stainless Steel

Material Conn Shield, 

Material

5 H HV Seal, Large Conn, H HV Seal, 2 SBR

Molded Large Conn, 

Molded

6 H HV Seal, Large Conn, H HV Seal, 1 SBR

Material Large Conn, 

Material

5 H HV Large Conn Lock, H HV Large 1 PA6T

Molded Conn Lock, 

Molded

6 H HV Large Conn Lock, H HV Large 1 PA6T

Material Conn Lock, 

Material

4 H HV Cable Clamp Base, H HV Cable 1 PA6T $0.10

Large Conn, Molded Clamp Base, 

Large Conn, 

Molded

5 H HV Cable Clamp Base, H HV Cable 1 PA6T

Large Conn, Material Clamp Base, 

Large Conn, 

Material

4 H HV Cable Clamp Top, H HV Cable 1 PA6T $0.06

Large Conn, Molded Clamp Top, 

Large Conn, 

Molded

5 H HV Cable Clamp Top, Large H HV Cable 1 PA6T

Conn, Material Clamp Top, 

Large Conn, 

Material

4 H HV TPA, Lrg Conn, Sig H HV TPA, Lrg 1 Commodity $0.03

Terms Conn, Sig Pricing

Terms

4 H HV Large Conn Asm, TCM H HV Large 1 $1.12

Module Conn Asm

5 H HV Large Conn Body, H HV Large 1 PA6T

Molded Conn Body, 

Molded

Design Profit®
Page 

7 of#

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Level Symbol Name Number Qty Material Piece Cost

6 H HV Large Conn Body, H HV Large 1 PA6T

Material Conn Body, 

Material

5 H HV Large Conn Shield H HV Large 2 Stainless 

Conn Shield Steel

6 H HV Large Conn Shield, H HV Large 1 Stainless 

Stamped Conn Shield, Steel

Stamped

7

H HV Large Conn Shield, H HV Large 1 Stainless Steel

Material Conn Shield, 

Material

5 H HV Seal, Large Conn, H HV Seal, 2 SBR

Molded Large Conn, 

Molded

6 H HV Seal, Large Conn, H HV Seal, 1 SBR

Material Large Conn, 

Material

5 H HV Large Conn Lock, H HV Large 1 PA6T

Molded Conn Lock, 

Molded

6 H HV Large Conn Lock, H HV Large 1 PA6T

Material Conn Lock, 

Material

4 H HV Cable Clamp Base, H HV Cable 1 PA6T $0.10

Large Conn, Molded Clamp Base, 

Large Conn, 

Molded

5 H HV Cable Clamp Base, H HV Cable 1 PA6T

Large Conn, Material Clamp Base, 

Large Conn, 

Material

4 H HV Cable Clamp Top, H HV Cable 1 PA6T $0.06

Large Conn, Molded Clamp Top, 

Large Conn, 

Molded

5 H HV Cable Clamp Top, Large H HV Cable 1 PA6T

Conn, Material Clamp Top, 

Large Conn, 

Material

4 H HV TPA, Lrg Conn, Sig H HV TPA, Lrg 1 Commodity $0.03

Terms Conn, Sig Pricing

Terms

Design Profit®
Page 

8 of#

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Level Symbol Name Number Qty Material Piece Cost

H HV JB Conn Cover Base H HV JB Conn 1 $0.12

Asm Cover Base 

Asm

4 H HV JB Conn Cover Base, H HV JB Conn 1 PBT GF15 $0.11

Molded Cover Base, 

Molded

5 H HV JB Conn Cover Base, H HV JB Conn 1 PBT GF15

Material Cover Base, 

Material

4 H HV JB Seal, Conn Cover, H HV JB Seal, 1 SBR $0.01

Molded Conn Cover, 

Molded

5 H HV JB Seal, Conn Cover, H HV JB Seal, 1 SBR

Material Conn Cover, 

Material

3 H HV JB Conn Asm H HV JB Conn 1 $0.29

Asm

4 H HV JB Conn Body, Molded H HV JB Conn 1 PBT GF15 $0.10

Body, Molded

5 H HV JB Conn Body, Material H HV JB Conn 1 PBT GF15

Body, Material

4 H HV JB Conn Jumper H HV JB Conn Jumper H HV JB Conn H HV JB Conn 2 Copper $0.06

Terminal Jumper 

Terminal

5 H HV JB Conn Jumper H HV JB Conn 1 Steel - 1008

Terminal, Stamped Jumper 

Terminal, 

Stamped

6 H HV JB Conn Jumper H HV JB Conn 1 Copper 

Terminal, Material Jumper 

Terminal, 

Material

4 H HV JB Conn Top, Molded H HV JB Conn 1 PBT GF15 $0.03

Top, Molded

5 H HV JB Conn Top, Material H HV JB Conn 1 PBT GF15

Top, Material

4 H HV JB Conn Shield Base H HV JB Conn 1 Zinc $0.05

Shield Base

5 H HV JB Conn Shield Base, H HV JB Conn 1 Zinc

Machined Shield Base, 

Machined

Design Profit®

Page 9 of #
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Level Symbol Name Number Qty Material Piece Cost

6 H HV JB Conn Shield Base, H HV JB Conn 1 Zinc

Trimmed Shield Base, 

Trimmed

7 H HV JB Conn Shield Base, H HV JB Conn 1 Zinc

Die Cast Shield Base, 

Die Cast

8 H HV JB Conn Shield Base, H HV JB Conn 1 Zinc

Material Shield Base, 

Material

3 H HV JB Conn Shield H HV JB Conn 1 Zinc $0.09

Shield

4 H HV JB Conn Shield H HV JB Conn 1 Zinc $0.09

Shield, 

Trimmed

5 H HV JB Conn Shield H HV JB Conn 1 Zinc

Shield, Die 

Cast

6 H HV JB Conn Shield, Material H HV JB Conn 1 Zinc

Shield, 

Material

3 H Screw, HV JB Conn Shield H Screw, HV 2 Commodity $0.00

JB Conn Pricing

Shield

3 H HV JB Conn Shield H HV JB Conn 1 Zinc $0.09

Shield

4 H HV JB Conn Shield H HV JB Conn 1 Zinc $0.09

Shield, 

Trimmed

5 H HV JB Conn Shield H HV JB Conn 1 Zinc

Shield, Die 

Cast

6 H HV JB Conn Shield, Material H HV JB Conn 1 Zinc

Shield, 

Material

3 H Screw, HV JB Conn Shield H Screw, HV 2 Commodity $0.00

JB Conn Pricing

Shield

3 H HV JB Conn Cover, H HV JB Conn 1 PBT GF15 $0.17

Molded Cover, 

Molded

4 H HV JB Conn Cover, Material H HV JB Conn 1 PBT GF15 $0.17

Cover, Material

Design Profit®
Page 

# of#

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Level Symbol Name Number Qty Material Piece Cost

H HV JB Cover Rear, Molded H HV JB 1 PA66 $0.25

Cover Rear, 

Molded

4 H HV JB Cover Rear, Material H HV JB Cover 1 PA66 $0.25

Rear, Material

3 H HV JB Cover Front, H HV JB 1 PA66 $0.11

Molded Cover Front, 

Molded

4 H HV JB Cover Front, Material H HV JB Cover 1 PA66 $0.11

Front, Material

2 H Bracket Clip Asm, HV H Bracket Clip 1 Nylon 6/6 $0.08

Cable, Taped On Asm, HV 

Cable, Taped 

On

3 H Bracket Clip ,HV Cable, H Bracket 1 Nylon 6/6 $0.07

Taped On Clip ,HV 

Cable, Taped 

On

4 H Bracket Clip ,HV Cable, H Bracket 1 Nylon 6/6 $0.07

Taped On, Material Clip ,HV Cable, 

Taped On, 

Material

3 H Crush Sleeve, Bracket H Crush 1 Steel - 1008 $0.01

Clip, HV Cable Sleeve, 

Bracket Clip, 

HV Cable

4 H Crush Sleeve, Bracket H Crush 1 Steel - 1008 $0.01

Clip, HV Cable, Stamped Sleeve, 

Bracket Clip, 

HV Cable, 

Stamped

5 H Crush Sleeve, Bracket Clip, H Crush 1 Steel - 1008

HV Cable, Stamped Sleeve, 

Bracket Clip, 

HV Cable, 

Material

2 H Black Duct Tape, 1" x 20.5" H Black Duct 1 Commodity $ 0.0300

Long Tape, 1" Wide Pricing

2 H HV Harness Lower Cover, H HV Harness 1 PA66 $0.20

#4, Molded Lower Cover, 

#4, Molded

Design Profit®
Page 

# of#

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Level Symbol Name Number Qty Material Piece Cost

H HV Harness Lower Cover, H HV Harness 1 PA66 $0.20

#4, Material Lower Cover, 

#4, Material

2 H Orange Tape, 5/8" x 10" H Orange 2 Commodity $0.01

Long Tape, 5/8" Pricing

Wide

2 H HV Harness Upper Cover, H HV Harness 1 PA66 $0.06

#4, Molded Upper Cover, 

#4, Molded

3 H HV Harness Upper Cover, H HV Harness 1 PA66 $0.06

#4, Material Upper Cover, 

#4, Material

2 H HV Harness Lower Cover H HV Harness 1 PA66 $0.19

Asm, #5 Lower Cover 

Asm, #5

3 H HV Harness Lower Cover H HV Harness 1 PA66 $0.18

Asm, #5 Lower Cover 

Asm, #5, 

Molded

4 H HV Harness Lower Cover H HV Harness 1 PA66 $0.18

Asm, #5, Material Lower Cover 

Asm, #5, 

Material

3 H Crush Sleeve Large, H Crush 1 Steel - 1008 $0.01

Bracket Clip, HV Cable Sleeve Large, 

Bracket Clip, 

HV Cable

4 H Crush Sleeve Large, H Crush 1 Steel - 1008 $0.01

Bracket Clip, HV Cable, Mold Sleeve Large, 

Bracket Clip, 

HV Cable, 

Mold

5 H Crush Sleeve Large, Bracket H Crush 1 Steel - 1008

Clip, HV Cable, Mate Sleeve Large, 

Bracket Clip, 

HV Cable, 

Mate

2 H Wrap Tie, HV Harness H Wrap Tie, 2 Commodity $0.01

Cover HV Harness Pricing

Cover
Design Profit

®

Page # of#

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Level Symbol Name Number Qty Material Piece Cost Weight

H HV Harness Upper Cover H HV Harness 1 PA66 $0.19

Asm, #5, Molded Upper Cover 

Asm, #5, 

Molded

3 H HV Harness Upper Cover H HV Harness 1 PA66 $0.19

Asm, #5, Material Upper Cover 

Asm, #5, 

Material

2 H Black Duct Tape, 3/4" x 14" H Black Duct 1 Commodity $0.02

Long Tape, 3/4" Pricing

Wide

2 H HV Harn Lower Cover H HV Harn 1 PA66 $0.23

Asm, #6 Lower Cover 

Asm, #6

3 H HV Harn Lower Cover H HV Harn 1 PA66 $0.21

Asm, #6, Molded Lower Cover 

Asm, #6, 

Molded

4 H HV Harn Lower Cover Asm, H HV Harn 1 PA66 $0.21

#6, Material Lower Cover 

Asm, #6, 

Material

3 H Crush Sleeve Large, H Crush Sleeve Large, H Crush H Crush 2 Steel - 1008 Steel - 1008 $0.01

Bracket Clip, HV Cable Sleeve Large, 

Bracket Clip, 

HV Cable

4 H Crush Sleeve Large, H Crush 1 Steel - 1008 $0.01

Bracket Clip, HV Cable, Mold Sleeve Large, 

Bracket Clip, 

HV Cable, 

Mold

5 H Crush Sleeve Large, Bracket H Crush 1 Steel - 1008

Clip, HV Cable, Mate Sleeve Large, 

Bracket Clip, 

HV Cable, 

Mate

2 H HV Harn Upper Cover H HV Harn 1 PA66 $0.12

Asm, #6, Molded Upper Cover 

Asm, #6, 

Molded

3 H HV Harn Upper Cover Asm, H HV Harn 1 PA66 $0.12

#6, Molded Upper Cover 

Asm, #6, 

Material

Design Profit®
Page 

# of#

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Level Symbol Name Number Qty Material Piece Cost Weight

H HV Harn Lower Cover H HV Harn 1 PA66 $0.79

Asm, #7 Lower Cover 

Asm, #7

3 H HV Harn Lower Cover H HV Harn 1 PA66 $0.77

Asm, #7, Molded Lower Cover 

Asm, #7, 

Molded

4 H HV Harn Lower Cover Asm, H HV Harn 1 PA66 $0.77

#7, Material Lower Cover 

Asm, #7, 

Material

3 H Crush Sleeve Large, H Crush 3 Steel - 1008 $0.01

Bracket Clip, HV Cable Sleeve Large, 

Bracket Clip, 

HV Cable

4 H Crush Sleeve Large, H Crush 1 Steel - 1008 $0.01

Bracket Clip, HV Cable, Mold Sleeve Large, 

Bracket Clip, 

HV Cable, 

Mold

5 H Crush Sleeve Large, Bracket H Crush 1 Steel - 1008

Clip, HV Cable, Mate Sleeve Large, 

Bracket Clip, 

HV Cable, 

Mate

2 H HV Harn Upper Cover H HV Harn 1 PA66 $0.42

Asm, #7, Molded Upper Cover 

Asm, #7, 

Molded

3 H HV Harn Upper Cover Asm, H HV Harn 1 PA66 $0.42

#7, Molded Upper Cover 

Asm, #7, 

Material

2 H Black Duct Tape, 3/4" x 14" H Black Duct 1 Commodity $0.02

Long Tape, 3/4" Pricing

Wide

1 H HV Harness Cover, #3, H HV Harness 1 PA66 $0.29

Molded Clamshell Cover, #3, 

Molded 

Clamshell

2 H HV Harness Cover, #3, H HV Harness 1 PA66 $0.29

Material Cover, #3, 

Material

Design Profit®
Page 

# of#

Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Level Symbol Name Number Qty Material Piece Cost Weight

H Black Duct Tape, 3/4" x H Black Duct 1 Commodity $0.01

10.25" Long Tape, 3/4" Pricing

Wide

1 H HV Harn Lower Cover H HV Harn 1 PA66 $0.49

Asm, #1 Lower Cover 

Asm, #1

2 H HV Harn Lower Cover, #1, H HV Harn 1 PA66 $0.43

Molded Lower Cover, 

#1, Molded

3 H HV Harn Lower Cover, #1, H HV Harn 1 PA66 $0.43

Material Lower Cover, 

#1, Material

2 H Push Pin, Harness Cover H Push Pin, 2 Commodity $0.03

Harness Cover Pricing

1 H DC-AC to Console Harness H DC-AC to 1 $2.15

Asm Console 

Harness Asm

2 H DC-AC to Console Harness H DC-AC to 1 $2.10

Console 

Harness

2 H HV Harn Cover with Snap H HV Harn 1 PA66 $0.03

Conn, Molded Cover with 

Snap Conn, 

Molded

3 H HV Harn Cover with Snap H HV Harn 1 PA66 $0.03

Conn, Material Cover with 

Snap Conn, 

Material

2 H Black Duct Tape, 3/4" x 6.5" H Black Duct 1 Commodity $0.01

Long Tape, 3/4" Pricing

Wide

2 H Black Duct Tape, 3/4" x 5" H Black Duct 1 Commodity $0.01

Long Tape, 3/4" Pricing

Wide

1 H HV Harn Upper Cover, #1, H HV Harn 1 PA66 $0.24

Molded Upper Cover, 

#1, Molded

2 H HV Harn Upper Cover, #1, H HV Harn 1 PA66 $0.24

Material Upper Cover, 

#1, Material

1 H Black Duct Tape, 3/4" x 15" H Black Duct 1 Commodity $0.02

Long Tape, 3/4" Pricing

Wide

Design Profit®

Page # of #
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Level Symbol Name Number Qty Material Piece Cost Weight

H Black Duct Tape, 3/4" x 53" H Black Duct 1 Commodity $0.07

Long Tape, 3/4" Pricing

Wide

1 H HV Harn Lower Cover, #2, H HV Harn 1 PA66 $0.10

Molded Lower Cover, 

#2, Molded

2 H HV Harn Lower Cover, #2, H HV Harn 1 PA66 $0.10

Material Lower Cover, 

#2, Material

1 H HV Harn Upper Cover, #2, H HV Harn 1 PA66 $0.04

Molded Upper Cover, 

#2, Molded

2 H HV Harn Upper Cover, #2, H HV Harn 1 PA66 $0.04

Material Upper Cover, 

#2, Material

1 H Black Duct Tape, 3/4" x 9.5" H Black Duct 1 Commodity $0.01

Long Tape, 3/4" Pricing

Wide

1 H Black Duct Tape, 3/4" x 15" H Black Duct 1 Commodity $0.02

Long Tape, 3/4" Pricing

Wide

1 H Tear Tape, 3/8" W H Tear Tape, 3/8" Wide x 11" ide x 11" H Tear Tape, H Tear Tape, 1 Commodity Commodity $0.01

Long 3/8" Wide Pricing

1 H Tear Tape, 3/8" Wide x 8.75" H Tear Tape, 1 Commodity $0.01

Long 3/8" Wide Pricing

1 H Tear Tape, 3/8" Wide x 18.5" H Tear Tape, 1 Commodity $0.01

Long 3/8" Wide Pricing

0 H Nut, HV Cable Mounts H Nut, HV 2 Commodity $0.04

Cable Mounts Pricing

0 H Nut, HV Cable Mounts H Nut, HV 5 Commodity $0.04

Cable Mounts Pricing

0 H Nut, HV Cable Mounts H Nut, HV 3 Commodity $0.04

Cable Mounts Pricing

0 H Cover Cable Pass Thru H Cover Cable 1 PA66 GF33 $0.33

Pass Thru

1 H Cover Cable Pass Thru, H Cover Cable 1 PA66 GF33 $0.33

Material Pass Thru, 

Material

0 H Stud Harness to Trans H Stud 1 Commodity $0.08

Bracket Harness to Pricing

Trans Bracket

Design Profit®

Page # of #
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Level Symbol Name Number Qty Material Piece Cost Weight

0 H Battery Service Disconect H Battery 1 $1.43

Plug Service 

Disconect 

Plug

1 H Base, Battery Service Plug H Base, 1 $0.17

Battery

Service Plug

2 H Base, Battery Service H Base, 1 $0.17

Plug-Molding Battery

Service 

Plug-Molding

3 H Base, Battery Service H Base, 1 PBT-GF20 $0.17

Plug-Material Battery Service 

Plug-MoldingMaterial

2 H Insert Stud, Battery Service H Insert Stud, 2 Commodity $0.04

Plug Battery Service Pricing

Plug

1 H Terminal, Battery Service H Terminal, 2 $0.52

Plug Battery

Service Plug

2 H Terminal, Battery Service H Terminal, 1 $0.52

Plug-Stamping Battery

Service 

PlugStamping

3 H Terminal, Battery Service H Terminal, 1 Copper $0.52

Plug- Material Battery Service 

Plug-Material

1 H Fuse, Service Plug H Fuse, 1 Commodity $1.25

Service Plug Pricing

1 H Screw, Battery Service Plug H Screw, 2 Commodity $0.06

Battery Service Pricing

Plug

1 H Washer, Battery Service H Washer, 2 Commodity $0.02

Plug Battery Service Pricing

Plug

1 H Cover, Battery Service H Cover, 1 $0.02

Plug Battery

Service Plug

2 H Cover, Battery Service H Cover, 1 Polypropylene $0.02

Plug-Material Battery Service 

Plug-Material

Design Profit®

Page # of #
Copyright 2005© Munro & Associates, Inc.
H Traction & HV Power Distribution Sub

Level Symbol Name Number Qty Material Piece Cost Weight

H Latch, Battery Service H Latch, 1 $0.10

Plug Battery

Service Plug

2 H Latch, Battery Service H Latch, 1 PA66 GF30 $0.10

Plug-Material Battery Service 

Plug-Material

1 H Label, Battery Service Plug H Label, 1 Commodity $0.10

Battery Service Pricing

Plug

Assembly Totals Report Totals

Analyzed Subs:# Piece Cost (Total):

Unanalyzed Subs: 0

Weight (Total): 13.4733 lb

Parts: #

Fasteners: #

Parts+Unanalyzed: #

Design Profit®

Page # of #
Copyright 2005© Munro & Associates, Inc.
Piece Cost Weight (Total)

(Total)

1.3550 lb 1.3550 lb

1.3250 lb # 1.3250 lb

1.3250 lb # 1.3250 lb

1.3250 lb # 1.3250 lb

1.3245 lb # 1.3245 lb

$0.87 1.3245 lb # 1.3245 lb

# 1.3245 lb ## 1.3245 lb

0.0005 lb # 0.0005 lb

0.0300 lb # 0.0300 lb

0.0300 lb # 0.0300 lb

0.1030 lb # 0.2060 lb

Piece Cost Weight (Total)

(Total)

0.4118 lb # 0.4118 lb

0.3404 lb # 0.3404 lb

0.3404 lb # 0.3404 lb

0.3404 lb # 0.3404 lb

0.1654 lb # 0.1654 lb

$0.18 0.1654 lb # 0.1654 lb

0.1750 lb # 0.1750 lb

$0.16 0.1750 lb # 0.1750 lb

# 0.1750 lb ## 0.1750 lb

0.0238 lb # 0.0714 lb

0.0105 lb # 0.0315 lb

Weight Piece Cost Weight (Total)

(Total)

0.0105 lb # 0.0315 lb

0.0133 lb # 0.0399 lb

0.0133 lb # 0.0399 lb

0.0133 lb # 0.0399 lb

$0.01 0.0133 lb # 0.0399 lb

0.0273 lb # 0.0819 lb

10.7551 lb # 10.7551 lb

9.7908 lb # 9.7908 lb

8.6115 lb # 8.6115 lb

7.9860 lb # 7.9860 lb

6.5236 lb # 6.5236 lb

0.3237 lb # 0.3237 lb

$0.66 0.3237 lb # 0.3237 lb

Weight Piece Cost Weight (Total)

(Total)

0.1405 lb 0.1405 lb

$0.00 0.0174 lb # 0.0522 lb

$0.18 0.0883 lb # 0.0883 lb

0.0014 lb # 0.0014 lb

0.1318 lb # 0.1318 lb

$0.32 0.0586 lb # 0.0586 lb

# 0.0586 lb ## 0.0586 lb

$0.06 0.0320 lb # 0.0640 lb

# 0.0160 lb ## 0.0640 lb

# 0.0080 lb # 0.0640 lb

$0.01 0.0046 lb # 0.0092 lb

# 0.0023 lb ## 0.0092 lb

0.0001 lb # 0.0002 lb

0.0129 lb # 0.0129 lb

$0.03 0.0129 lb # 0.0129 lb

Weight Piece Cost Weight (Total)

(Total)

0.0144 lb 0.0144 lb

$0.03 0.0144 lb # 0.0144 lb

0.1318 lb # 0.1318 lb

$0.32 0.0586 lb # 0.0586 lb

# 0.0586 lb ## 0.0586 lb

$0.06 0.0320 lb # 0.0640 lb

# 0.0160 lb ## 0.0640 lb

# 0.0080 lb # 0.0640 lb

$0.01 0.0046 lb # 0.0092 lb

# 0.0023 lb ## 0.0092 lb

0.0001 lb # 0.0002 lb

0.0127 lb # 0.0127 lb

$0.03 0.0127 lb # 0.0127 lb

Weight Piece Cost Weight (Total)

(Total)

0.0144 lb 0.0144 lb

$0.03 0.0144 lb # 0.0144 lb

0.1318 lb # 0.1318 lb

$0.32 0.0586 lb # 0.0586 lb

# 0.0586 lb ## 0.0586 lb

$0.06 0.0320 lb # 0.0640 lb

# 0.0160 lb ## 0.0640 lb

# 0.0080 lb # 0.0640 lb

$0.01 0.0046 lb # 0.0092 lb

# 0.0023 lb ## 0.0092 lb

0.0001 lb # 0.0002 lb

0.2451 lb # 0.2451 lb

$0.74 0.1454 lb # 0.1454 lb

# 0.1454 lb ## 0.1454 lb

$0.03 0.0165 lb # 0.0330 lb

Weight Piece Cost Weight (Total)

(Total)

# 0.0165 lb ## 0.0330 lb

# 0.0165 lb # 0.0330 lb

$0.01 0.0065 lb # 0.0130 lb

# 0.0065 lb ## 0.0130 lb

$0.29 0.0537 lb # 0.0537 lb

# 0.0537 lb ## 0.0537 lb

0.0174 lb # 0.0174 lb

$0.10 0.0174 lb # 0.0174 lb

0.0103 lb # 0.0103 lb

$0.06 0.0103 lb # 0.0103 lb

0.0004 lb # 0.0004 lb

0.2451 lb # 0.2451 lb

$0.74 0.1454 lb # 0.1454 lb

Weight Piece Cost Weight (Total)

(Total)

# 0.1454 lb ## 0.1454 lb

$0.03 0.0165 lb # 0.0330 lb

# 0.0165 lb ## 0.0330 lb

# 0.0165 lb # 0.0330 lb

$0.01 0.0065 lb # 0.0130 lb

# 0.0065 lb ## 0.0130 lb

$0.29 0.0537 lb # 0.0537 lb

# 0.0537 lb ## 0.0537 lb

0.0174 lb # 0.0174 lb

$0.10 0.0174 lb # 0.0174 lb

0.0103 lb # 0.0103 lb

$0.06 0.0103 lb # 0.0103 lb

0.0004 lb # 0.0004 lb

Weight Piece Cost Weight (Total)

(Total)

0.0680 lb # 0.0680 lb

0.0599 lb # 0.0599 lb

$0.11 0.0599 lb # 0.0599 lb

0.0081 lb # 0.0081 lb

$0.01 0.0081 lb # 0.0081 lb

0.1297 lb # 0.1297 lb

0.0534 lb # 0.0534 lb

$0.10 0.0534 lb # 0.0534 lb

0.0129 lb # 0.0258 lb

$0.06 0.0129 lb # 0.0258 lb

# 0.0129 lb ## 0.0258 lb

0.0129 lb # 0.0129 lb

$0.03 0.0129 lb # 0.0129 lb

0.0376 lb # 0.0376 lb

$0.05 0.0376 lb # 0.0376 lb

Weight Piece Cost Weight (Total)

(Total)

# 0.0376 lb ## 0.0376 lb

# 0.0376 lb # 0.0376 lb

# 0.0376 lb # 0.0376 lb

0.0672 lb # 0.0672 lb

0.0672 lb # 0.0672 lb

$0.09 0.0672 lb # 0.0672 lb

# 0.0672 lb ## 0.0672 lb

0.0054 lb # 0.0108 lb

0.0672 lb # 0.0672 lb

0.0672 lb # 0.0672 lb

$0.09 0.0672 lb # 0.0672 lb

# 0.0672 lb ## 0.0672 lb

0.0054 lb # 0.0108 lb

0.0999 lb # 0.0999 lb

0.0999 lb # 0.0999 lb

Weight Piece Cost Weight (Total)

(Total)

0.1196 lb # 0.1196 lb

0.1196 lb # 0.1196 lb

0.0523 lb # 0.0523 lb

0.0523 lb # 0.0523 lb

0.0393 lb # 0.0393 lb

0.0321 lb # 0.0321 lb

0.0321 lb # 0.0321 lb

0.0072 lb # 0.0072 lb

0.0072 lb # 0.0072 lb

$0.01 0.0072 lb # 0.0072 lb

0.0082 lb # 0.0082 lb

0.0948 lb # 0.0948 lb

Weight Piece Cost Weight (Total)

(Total)

0.0948 lb # 0.0948 lb

0.0008 lb # 0.0016 lb

0.0253 lb # 0.0253 lb

0.0253 lb # 0.0253 lb

0.0950 lb # 0.0950 lb

0.0854 lb # 0.0854 lb

0.0854 lb # 0.0854 lb

0.0096 lb # 0.0096 lb

0.0096 lb # 0.0096 lb

$0.01 0.0096 lb # 0.0096 lb

0.0018 lb # 0.0035 lb

Piece Cost Weight (Total)

(Total)

0.0932 lb 0.0932 lb

0.0932 lb # 0.0932 lb

0.0035 lb # 0.0035 lb

0.1217 lb # 0.1217 lb

0.1025 lb # 0.1025 lb

0.1025 lb # 0.1025 lb

0.0096 lb # 0.0192 lb

0.0096 lb # 0.0192 lb

$0.01 0.0096 lb # 0.0192 lb

0.0576 lb # 0.0576 lb

0.0576 lb # 0.0576 lb

Piece Cost Weight (Total)

(Total)

0.4237 lb 0.4237 lb

0.3949 lb # 0.3949 lb

0.3949 lb # 0.3949 lb

0.0096 lb # 0.0288 lb

0.0096 lb # 0.0288 lb

$0.01 0.0096 lb # 0.0288 lb

0.2086 lb # 0.2086 lb

0.2086 lb # 0.2086 lb

0.0033 lb # 0.0033 lb

0.1411 lb # 0.1411 lb

0.1411 lb # 0.1411 lb

Piece Cost Weight (Total)

(Total)

0.0026 lb 0.0026 lb

0.2151 lb # 0.2151 lb

0.2128 lb # 0.2128 lb

0.2128 lb # 0.2128 lb

0.0012 lb # 0.0023 lb

0.3974 lb # 0.3974 lb

0.3831 lb # 0.3831 lb

0.0114 lb # 0.0114 lb

0.0114 lb # 0.0114 lb

0.0016 lb # 0.0016 lb

0.0013 lb # 0.0013 lb

0.1173 lb # 0.1173 lb

0.1173 lb # 0.1173 lb

0.0038 lb # 0.0038 lb

Piece Cost Weight (Total)

(Total)

0.0133 lb 0.0133 lb

0.0457 lb # 0.0457 lb

0.0457 lb # 0.0457 lb

0.0182 lb # 0.0182 lb

0.0182 lb # 0.0182 lb

0.0024 lb # 0.0024 lb

0.0038 lb # 0.0038 lb

0.0011 lb # 0.0011 lb

0.0009 lb # 0.0009 lb

0.0019 lb # 0.0019 lb

0.0134 lb # 0.0268 lb

0.0134 lb # 0.0670 lb

0.0134 lb # 0.0402 lb

0.1661 lb # 0.1661 lb

0.1661 lb # 0.1661 lb

0.0340 lb # 0.0340 lb

Piece Cost Weight (Total)

(Total)

0.3294 lb # 0.3294 lb

0.1168 lb # 0.1168 lb

0.0968 lb # 0.0968 lb

0.0968 lb # 0.0968 lb

0.0100 lb # 0.0200 lb

0.0462 lb # 0.0924 lb

0.0462 lb # 0.0924 lb

0.0462 lb # 0.0924 lb

0.0586 lb # 0.0586 lb

0.0118 lb # 0.0118 lb

0.0000 lb # 0.0000 lb

0.0000 lb # 0.0000 lb

0.0000 lb # 0.0000 lb

Piece Cost Weight (Total)

(Total)

0.0498 lb 0.0498 lb

0.0498 lb # 0.0498 lb

0.0000 lb # 0.0000 lb

Preassembled Totals

Analyzed Subs:

Unanalyzed Subs:

Parts:

Fasteners:

Parts+Unanalyzed:

Bill of Materials S/A & Components for H Traction & HV Power Distribution

Name

o H Bracket Asm - Trans

o H Bracket Asm

o H Weld Nut - 6mm Sqr

o H Bracket Clip

o H Bracket Asm - Dash

o H Bracket

o H Bracket Stiffener

o H Bushing Asm

o H Anti Crush Insert

o H Cable Asm HV

o A H Cable Asm HV Covered

o H Bracket Asm - Trans

o H Bracket Asm - Dash

o H Bolt 

o H Bolt

o H Nut

o H Nut 

o H Nut

o H Cover Cable Pass Thru

o H Stud

o Y H Battery Service Disconnect Asm

o Y H Battery Service Disconnect Asm

o H Base Battery Service Plug Sub-Asm

o H Base Battery Service Plug Body

o H Insert Nut

o H Terminal, Battery Service

o H Fuse, Service Plug

o H Screw, Service Plug

o H Washer, Battery Service

o H Cover, Battery Service Plug

o H Latch, Battery Service Plug

o H Label, Battery Service Plug

o A H Cable Asm HV Covered

o B H HV Harn Asm w/ JB & Tape

o H HV Harness Cover #3

o Black Duct Tape 3/4" 10.25"

o H HV Harness Lwr Cover Asm

o H HV Harness Lwr Cover #1

o H Push Pin Harness Cover

o X H DC-AC to Console Harness

o H HV Harness Upr Cover #1

o H Black Duct Tape 3/4" x 15"

o H Black Duct Tape 3/4" x 53"
o H HV Harness Lwr Cover #2

o H HV Harness Upr Cover #2

o H Black Duct Tape 3/4" x 9.5"

o H Black Duct Tape 3/4" x 15"

o H Tear Tape 3/8"W x 11"L

o H Tear Tape 3/8"W x 8.75"L

o H Tear Tape 3/8"W x 18.5"L

o X H DC-AC to Console Harness

o 160" 18Ga Wire

o 160" 16Ga Wire

o 10 x 1.5mm Unsealed Conn

o 6 x 1.5mm Unsealed Conn

o 1.5mm Female Spade Terminals

o TPAs

o 65" - 1/4" Orange Convolute

o 235" - 3/4" Orange Tape

o 37" - 3/4" Black Duct Tape

o 24" - 3/4" Black Fabric

o Edge Bitter Clip

o Std Tape on Clips

o Modified Tape on Clips

o Strap on Clips

o H HV Harness Cover w/ Snap

o H Black Duct Tape 3/4" x 6.5"

o H Black Duct Tape 3/4" x 5"

o B H HV Harn Asm w/ JB & Tape

o C H HV Harn Asm w/ Tape & Conn

o H Bracket Clip Asm, HV Cable

o H Bracket Clip, HV Cable

o H Crush Sleeve Bracket

o H Black Duct Tape 1" x 20.5"

o H HV Harness Lower Cover #4

o H Orange Tape 5/8" x 10"L

o H HV Harness Upper Cover #4

o H HV Harness Lower Cover Asm #5

o H Crush Sleeve Large, Bracket

o H Wrap Tie, HV Harness Cover

o H HV Harness Upper Cover Asm #5

o H Black Duct Tape 3/4" x 14"

o H HV Harn Lower Cover Asm #6

o H Crush Sleeve Large, Bracket

o H HV Harn Upper Cover Asm #6

o H HV Harn Lower Cover Asm #7

o H Crush Sleeve Large, Bracket

o H HV Harn Upper Cover Asm #7

o H Black Duct Tape 3/4" x 14"

o C H HV Harn Asm w/ Tape & Conn
o D H HV Harn Asm w/ Tape & Terminals

o H HV JB Conn Cover Base Asm

o H HV JB Conn Cover Base

o H HV JB Seal Conn Cover

o H HV JB Conn Asm

o H HV JB Conn Body

o H HV JB Conn Jumper Terminal

o H HV JB Conn Top

o H HV JB Conn Shield Base

o H HV JB Conn Shield

o H Screw HV JV Conn Shield

o H HV JB Conn Shield

o H Screw HV JV Conn Shield

o H HV JB Conn Cover Asm

o H HV JB Cover Rear

o H HV JB Cover Front

o D H HV Harn Asm w/ Tape & Terminals

o E H HV Harn Misc Commodity Hardware Notes

o H HV Cable Boot

o H HV Cable Boot Mount Asm

o H HV Boot Mount Bolt

o H Wrap Tie, HV Harness Mount

o H HV Medium Conn Asm AC

o H HV Medium Conn Body

o H HV Medium Conn Shield

o H HV TPA Medium Conn

o H HV Cable Clamp Base Curved

o H HV Cable Clamp Cover Curved

o H HV Medium Conn Asm DC-DC

o H HV Medium Conn Body

o H HV Medium Conn Shield

o H HV Seal Medium Conn

o H HV TPA Medium Conn

o H HV Cable Clamp Base Straight

o H HV Cable Clamp Cover Straight

o H HV Medium Conn Asm BEC

o H HV Medium Conn Body

o H HV Medium Conn Shield

o H HV Seal Medium Conn

o H HV TPA Medium Conn

o H HV Large Conn Asm BEC

o H HV Large Conn Body

o H HV Large Conn Shield

o H HV Seal Large Conn

o H HV Large Conn Lock

o H HV Cable Clamp Base, Lar

o H HV Cable Clamp Top Large

o H HV TPA Lrg Conn Sig Terms

o H HV Large Conn Asm TCM
o H HV Large Conn Body

o H HV Large Conn Shield

o H HV Seal Large Conn

o H HV Large Conn Lock

o H HV Cable Clamp Base, Lar

o H HV Cable Clamp Top Large

o H HV TPA Lrg Conn Sig Terms

o E H HV Harn Misc Commodity Hardware Asm

o F H HV Harn Misc Commodity Hardware - AC #1 (28")

o G H HV Harn Misc Commodity Hardware - DC-DC #1 (51")

o H H HV Harn Misc Commodity Hardware - Trans (152")

o I H HV Harn Misc Commodity Hardware - BEC (154")

o J H HV Harn Misc Commodity Hardware - Comm FB

o 4.5" - 13mm Adhesive Heat Shrink

o 5" - 3/8" Butyl Strip Caulk

o 3" - 25mm Orange Convolute

o 35" - 19mm Orange Convolute

o 51" - 16mm Orange Convolute

o Std Tape on Clips

o Large Tape on Clip

o Strap on Clips

o Tape on Label

o 1467" 3/4" Orange Tape

o 17" 3/4" Black Tape

o 75" 3/4" Black Duct Tape

o 13.5" - 1" Black Fabric

o 18" - 80mm Wide Foil & Mesh Tape

o F H HV Harn Misc Commodity Hardware - AC #1 (28")

o 56" - 2.72mm Shielded Cable

o JB Seal Keepers (Red)

o JB Conn Seals (Drk Green)

o 2.8mm Female Terminals

o Conn Seals (Blue)

o Med Grnd Caps & Ferrules

o G H HV Harn Misc Commodity Hardware - DC-DC #1 (51")

o 102" - 2.72mm Shielded Cable

o JB Seal Keepers (Red)

o JB Conn Seals (Drk Green)

o 2.8mm Female Terminals

o Conn Seals (Blue)

o Med Grnd Caps & Ferrules

o H H HV Harn Misc Commodity Hardware - Trans (152")

o 304" - 5.49mm Shielded Cable

o Conn Seals, Large (Lt Green)

o Lrg Grnd Caps & Ferrules

o 5.5mm Female Terminals
o Terminal Align Guides

o I H HV Harn Misc Commodity Hardware - BEC (154")

o 308" - 2.72mm Shielded Cable

o Conn Caps (Orange)

o Conn Seals (Blue)

o Med Grnd Caps & Ferrules

o JB Seal Keepers (Red)

o JB Conn Seals (Drk Green)

o 2.8mm Female Terminals

o J H HV Harn Misc Commodity Hardware - Comm FB

o 730" - 18 gauge Wire

o 2 Cavity 1.5mm Seal Conn

o 1.5mm Female Spade Terms & Seals

o 1.0mm Male Spade Terms & Seals
 Power Distribution

Function Qty Notes Cost from MAQS

1

HV Cable to Trans 1 PMAP

Bracket HV Cable to Trans 1 Commodity

HV Cable to Trans 1 PMAP

1

HV Cable to Dash 1 PMAP

Dash Bracket 1 PMAP

Dash Bracket 3 PMAP

Dash Bracket 1 PMAP

1

1 PMAP

1 PMAP

1 PMAP

Trans Cable Bracket 2 Commodity

Bracket front of Dash 3 Commodity

HV Cable to Dash Bracket 2 Commodity

HV Cable to Floor 5 Commodity

HV Cable to Floor 3 Commodity

HV Cables Battery to Floor 1 PMAP

Harness to Trans Bracket 1 Commodity

1 PMAP

1 PMAP

1 PMAP

1 PMAP

2 Commodity

2 PMAP

1 Commodity

2 Commodity

2 Commodity

1 PMAP

1 PMAP

1 Commodity

1

1 PMAP

1 PMAP

Fasten Cover 1 Commodity

1 PMAP

1 PMAP

Secure Cover 2 Commodity

1 PMAP

1 PMAP

1 Commodity

1 Commodity
1 PMAP

1 PMAP

1 Commodity

1 Commodity

1 Commodity

1 Commodity

1 Commodity

1 PMAP

1 Commodity - PMAP note

1 Commodity - PMAP note

1 Commodity - PMAP note

1 Commodity - PMAP note

8 Commodity - PMAP note

2 Commodity - PMAP note

1 Commodity - PMAP note

1 Commodity - PMAP note

1 Commodity - PMAP note

1 Commodity - PMAP note

1 Commodity - PMAP note

1 Commodity - PMAP note

2 Commodity - PMAP note

3 Commodity - PMAP note

1 PMAP

1 Commodity

1 Commodity

1 PMAP

1 PMAP

1 PMAP

1 PMAP

1 PMAP

1 Commodity

1 PMAP

1 Commodity

1 PMAP

1 PMAP

1 PMAP

2 Commodity

1 PMAP

1 Commodity

1 PMAP

2 PMAP

1 PMAP

1 PMAP

3 PMAP

1 PMAP

1 Commodity

1 PMAP
1 PMAP

1 PMAP

1 PMAP

1 PMAP

1 PMAP

1 PMAP

1 PMAP

1 PMAP

1 PMAP

1 PMAP

2 Commodity

1 PMAP

2 Commodity

1 PMAP

1 PMAP

1 PMAP

1 PMAP

1 Commodity - PMAP note

1 PMAP

1 PMAP

3 Commodity

1 Commodity

1 PMAP

1 PMAP

2 PMAP

2 Commodity

1 PMAP

1 PMAP

1 PMAP

1 PMAP

2 PMAP

2 PMAP

2 Commodity

1 PMAP

1 PMAP

1 PMAP

1 PMAP

2 PMAP

2 PMAP

2 Commodity

1 PMAP

1 PMAP

2 PMAP

2 PMAP

1 PMAP

1 PMAP

1 PMAP

1 Commodity

1 PMAP
1 PMAP

2 PMAP

2 PMAP

1 PMAP

1 PMAP

1 PMAP

1 Commodity

1 Commodity - PMAP note

1 PMAP

1 PMAP

1 PMAP

1 PMAP

1 PMAP

1 Commodity - PMAP note

1 Commodity - PMAP note

1 Commodity - PMAP note

1 Commodity - PMAP note

1 Commodity - PMAP note

3 Commodity - PMAP note

1 Commodity - PMAP note

2 Commodity - PMAP note

1 Commodity - PMAP note

1 Commodity - PMAP note

1 Commodity - PMAP note

1 Commodity - PMAP note

1 Commodity - PMAP note

1 Commodity - PMAP note

1 PMAP

1 Commodity - PMAP note

2 Commodity - PMAP note

2 Commodity - PMAP note

4 Commodity - PMAP note

2 Commodity - PMAP note

4 Commodity - PMAP note

1 PMAP

1 Commodity - PMAP note

2 Commodity - PMAP note

2 Commodity - PMAP note

4 Commodity - PMAP note

2 Commodity - PMAP note

4 Commodity - PMAP note

1 PMAP

1 Commodity - PMAP note

4 Commodity - PMAP note

4 Commodity - PMAP note

4 Commodity - PMAP note
4 Commodity - PMAP note

1 PMAP

1 Commodity - PMAP note

2 Commodity - PMAP note

2 Commodity - PMAP note

4 Commodity - PMAP note

2 Commodity - PMAP note

2 Commodity - PMAP note

4 Commodity - PMAP note

1 PMAP

1 Commodity - PMAP note

3 Commodity - PMAP note

6 Commodity - PMAP note

4 Commodity - PMAP note
Active Rate

2008

A. CARBON & ALLOY STEELS (SAE1000-9000 SERIES)

A1. CARBON STEEL

A1.1 10XX Plain Carbon Steel Mn 1.00% Max

Low Carbon Steel SAE J403 1008/1010 Coil Brackets, Spacers LC-Steel-1000S, Coil $ 0.45

Medium Carbon Steel SAE J403 1018 Coil Splash Pans, Dampers, Windage Tray MC-Steel-1000S, Coil $ 0.55

High Carbon Steel SAE J403 1040 Coil HC-Steel-1000S, Coil $ 0.65

Spring Steel SAE 1050 Coil Low/Moderate Stress Spring Clips SPR-Steel, Coil $ 0.65

Low Carbon, Hot Dip Galvanized 

Steed.

SAE J403 1008/1010 Coil PCV Baffles LC-GSteel-1000S, Coil $ 0.48

Medium Carbon Steel SAE J403 1018 Bar MC-Steel-1018, Bar $ 0.74

High Carbon Steel SAE J403 1040 Bar (1-3") HC-Steel-1040S, Bar $ 0.80

A1.2 11XX Resulfurized Steel

A1.3 12XX Resulfurized and Rephosphorized

12L14 Leaded Bar Bar Bushings, Inserts, Couplings LC-Steel-1214, Bar $ 0.62

1215 Replacement to 12L14 Bar Bushings, Inserts, Couplings LC-Steel-1215, Bar $ 0.62

Low Carbon Steel Tubing 1215 Tube Metal Tubing coolant lines, oil lines, etc. LC-Steel-1215, Tubing $ 0.62

A1.4 15XX Plain Carbon Mn 1.00-1.65%

A2. MANGANESE STEELS

A2.1 13XX Mn 1.75%

A3. NICKEL STEELS

A3.1 23XX Ni 3.50%

A3.2 25XX Ni 5.00%

Supplemental 

Specification 

Information

Cat. Item Material Description Industry Specification Application Examples Material Class

 Carbon Ranges: Low 0.05-0.15%, Mid. 0.16-0.29%, High 0.30-1.10%, Ultra High 1-2%

A. Carbon/Alloy Steel

B. HSLA & Micro Alloy

C. Stainless Steel 

D. Cast Iron

H. Titanium Alloys

G. Magnesium Alloys

F. Powder Metal J. Copper Alloys

E. Aluminum Alloys

M.

Q. Thermoplastics

R Thermosets.

P. S. Thermoplastic Elast.

N.

L Cobalt Alloys. O.

K. Nickel Alloys T.

U Automotive Fluids.

V. Plating & Coatings

W Misc.

X.

Y.

A4. NICKEL-CHROMIUM STEELS

A4.1 31XX Ni 1.25% Cr0.65% or 0.80%

A4.2 32XX Ni 1.25% Cr1.07% 

A4.3 33XX Ni 3.50% Cr1.50% or 1.57%

A4.4 34XX Ni 3.00% Cr0.77% 

A5. MOLYBDENUM STEELS

A5.1 40XX Mo 0.20 or 0.25% or 0.25%Mo & 0.042S

A5.2 44XX Mo 0.40% or 0.52%

A6. CHROMIUM-MOLYBDENUM (CHROMOLY) STEELS

A6.1 41XX

41xx Bar Injector Body A-Steel-41XXS, Bar $ 0.78

Chrome-Moly-Vanadium Steel 32CrMoV13 Bar Bearings, Crank shafts MA-Steel-CrMoV, Bar $ 0.98

Chrome-Moly-Vanadium Steel 32CrMoV13 Bearings, Crank shafts $ 6.65

4130 Bar Ø1-2" Pinion Gears A-Steel-4140, Bar 1-2" $ 0.74

4130 Bar Ø3-4" Pinion Gears A-Steel-4140, Bar 3-4" $ 0.94

4140RH 42CrMoS4 Bar Crankshafts, axle journals, gears, pushrods. A-Steel-4140, Bar $ 0.78

4140 SAE 4140 Bar (0.25-1") A-Steel-4140, Bar 0.25-

1"

$ 1.23

4140 Bar Ø0.875-2.75" A-Steel-4140, Bar 

0.875-2.75"

$ 0.78

4140 SAE 4140 Plate (0.125-0.7") A-Steel-4140, Plate $ 1.84

4140 - Tight Thickness Tolerance SAE 4140 Plate ((0.125-0.5") A-Steel-4140, Plate 

Tight Tolerance

$ 3.47

4130 Spring Steel Heat-Treatable C 0.28/0.33 Si 0.20/0.35, Mn 0.40/0.60, Cr 

0.80/1.10, P&S 0.025 Max, Mo 0.15/0.25

Coil Direct Injector Spring Clips HC-Steel-4130, Coil $ 1.18

4130 C 0.28/0.33 Si 0.20/0.35, Mn 0.40/0.60, Cr 

0.80/1.10, P&S 0.025 Max, Mo 0.15/0.25

Coil, 0.04" to 0.125" HC-Steel-4130, Coil 

0.04"-0.125"

$ 1.18

4130 Tight Thickness Tolerance. C 0.28/0.33 Si 0.20/0.35, Mn 0.40/0.60, Cr 

0.80/1.10, P&S 0.025 Max, Mo 0.15/0.25

Coil, 0.05" to 0.08", 

Tight Thickness 

Tolerance

HC-Steel-4130, Coil 

0.04"-0.08"

$ 2.79

A7. NICKLE-CHROMIUM-MOLYBDENUM STEELS

A7.1 43XX Ni 1.82%, Cr 0.50-0.80%, Mo 0.25%

300M SAE 4340Mod Vacuum melted high 

strength, super alloy.

Drive shafts, Con. Rods MA-Steel-300M, Bar $ 0.89

Cr 0.50% 0r 0.80% or 0.95%, Mo 0.12% or 0.20% or 0.25% or 0.30%
300M SAE 4340Mod Round Bar - Ø1" Drive shafts, Con. Rods MA-Steel-300M, Bar 

Ø1"

$ 5.48

300M SAE 4340Mod Round Bar - Ø2" Drive shafts, Con. Rods MA-Steel-300M, Bar 

Ø2"

$ 7.72

Ni-Chrome-Moly SAE 4330/4340 Bar 1-7" Planetary Gear Carrier, Shafts MA-Steel-43XXM, Bar $ 1.08

A7.2 43BVXX Ni 1.82%, Cr 0.50 Mo 0.12% or 0.35%, 

V0.03% min

A7.3 47XX Ni 1.05%, Cr 0.45 Mo 0.20% or 0.35%

A7.4 86XX Ni 0.55%, Cr 0.50 Mo 0.20% 

8620, Case Hardening Steel SAE 8620, 21NiCrMoS5 Bar Driving Bevel Gears, Crown Wheels, Gears, 

Shafts, Bolts for automotive and gear 

components.

A-Steel-8620, Bar $ 0.70

8620, Case Hardening Steel SAE 8620 Bar 1-4" Driving Bevel Gears, Crown Wheels, Gears, 

Shafts, Bolts for automotive and gear 

components.

A-Steel-8620, Bar 1-4" $ 0.78

A8. NICKLE-MOLYBDENUM STEELS

A8.1 46XX Ni 0.85% or 1.82%, Mo 0.20 or 0.25%

A8.2 48XX Ni 3.50%, Mo 0.25%

A9. CHROMIUM STEELS

A9.1 50XX Cr 0.27% or 0.40% or 0.50% or 0.65%

A9.2 50XXX Cr 0.50%, C 1.00%

A9.3 50BXX Cr 0.28% or 0.50%

A9.4 51XX Cr 0.80% or 0.87% or 0.92% or 1.00% or 

1.05%.

SAE 5115 C0.15, Si0.25, Mn0.50, Cr0.60, Bar A-Steel-51XX, Bar $ 1.00

SAE 5140/5145 Bar Gear, Shafts A-Steel-5140, Bar $ 1.00

A9.5 51XXX Cr 1.02%, C 1.00% Min.

Chromium Steel, High Carbon, 

Bearing Grade, Unpolished Mill 

Finished, Annealed

SAE 52100 Bar >0.5" Bearing Races A-Steel-52100 Bar $ 1.00

A9.6 51BXX Cr 0.80%

A9.7 52XXX Cr 1.45% C 1.00% Min.

52XXX Sprag's A-Steel-52XX, Ext. $ 1.00

Bar. Tight Tolerance

$ 1.00

A10. CHROMIUM-VANADIUM STEELS

A10.1 61XX Cr 0.60% or 0.80% or 0.95%, V 0.10% or 

0.15%

SAE 6150 Bar 1-8" Park pawl, park gear $ 0.67

A11. TUNGSTEN-CHROMIUM STEELS

A11.1 72XX W1.75%, Cr 0.75%

A12. SILICON-MANGANESE STEELS

A12.1 92XX Si 1.40% or 2.00%, Mn 0.65% or 0.82% or 

0.85%, Cr 0.00% or 0.65%

B. HIGH STRENGTH LOW ALLOY (HSLA) and MICRO ALLOY STEELS

B1. HSLA Steels

B1.1 940-980X C0.21-0.26%, Mg1.35-1.65%, P0.04%, 

S0.05%, Si0.90%Max, w. Niobium, 

Vanadium, Nitrogen.

B2. Micro Alloy Steels

A2.1 Mn 1.75%

080X47 C0.45/0.50%, Si.10/0.35%, Mn0.70/0.90%, 

S0.06/0.08%

Typical Air Cooled 

Forging Steel

C38+N

C0.36/0.40%, Si 0.50/0.65%, 

Mn1.40/1.55%, S0.03/0.065%, 

V0.015/0.020% or N0.015/0.20%

Typical Air Cooled 

Forging Steel

VANARD 925 C0.37/0.42%, Si 0.15/0.24%, 

Mn1.10/1.50%, S0.05/0.08%, V0.08/0.13%

Typical Air Cooled 

Forging Steel

C70S6 C0.72%, Si0.22%, Mn0.49%, S0.062%, 

V0.04%

Typical Air Cooled 

Forging Steel Forged fractured split rods MA-Steel-C70S6, Bar $ 0.70

C70S6 C0.72%, Si0.22%, Mn0.49%, S0.062%, 

V0.04%

Typical Air Cooled 

Forging Steel Forged fractured split rods $ 2.60

36MnVS4 Bar

Crankshafts, Cracked Forged Rods, Short and 

Long-shaft Ball Points, threaded heavy duty 

anchor bolts.

MA-Steel-MnVS, Bar $ 0.73

C. STAINLESS STEELS (SAE100-600Series)
C1. 300 Series - Austenitic Chromium-Nickel Alloys

C1.1 304 General Purpose

304 Bar Valves and Tubing S-Steel-304, Bar $ 1.65

304/304L Coil Exhaust Systems, Fuel tanks S-Steel-304, Coil $ 1.64

304/304L Sheet or Cast Housings for Catalytic Converters and 

Turbochargers.

S-Steel-304, Cast $ 1.39

304 Tube Fuel Rail S-Steel-304, Tube $ 1.65

C1.1.1 316 Mo added to increase corrosion resistance.

316 Bar Valves and Tubing S-Steel-316, Bar $ 2.44

316/316L C reduced for weldability Coil S-Steel-316, Coil $ 2.72

316/316L C reduced for weldability Cast/Sheet Housings for Catalytic Converters and 

Turbochargers.

S-Steel-316, Cast $ 2.82

316N N added to increase strength

316F S&P added for machinability

317 More Mo and Cr added for better corrosion 

resistance.

C1.1.2 309/309S CR & Ni increased for high temperature.

310/310S Same as 309, only more so. Internal Components for Turbochargers (e.g.. 

Rotors)

S-Steel-310, Cast $ 4.23

314 Si increased for highest heat resistance.

C1.1.3 302 High C for increased strength

304L C reduced for weldability

308 Higher Cr & Ni used primarily for welding

321 Ti added to prevent carbide precipitation.

C1.1.4 305 Ni increased to lower work hardening.

384 More Ni to lower work hardening

S30430 Cu added to improve cold working.

C1.1.5 303 S added to improve machining.

303Se Se (Selenium) added for better machined 

surfaces.

303 Bar Valves and Tubing S-Steel-303, Bar $ 1.55

303L Bar Valves and Tubing S-Steel-303L, Bar $ 1.65

C1.1.6 301 Cr and Ni lowered to increase work 

hardening.

C1.1.7 MISC.

21-2N/21/4N (EV8) Austenitic Precipitation Hardening Chrome 

Manganese Nickel Steel: Cr:23/20%, 

Ni4.50/3.25%, Mn: 10/8% etc.

Bar Intake & Exhaust Valves S-Steel-21_14N, Bar $ 7.56

Harden by cold working, can not be hardened by heat treating, Non Magnetic in annealed condition. Excellent 

corrosion resistance and usually good formability.

C2. 400 Series Ferritic Chromium Alloys

C2.1 430 General Purpose

C.2.1.1 442 Cr Increased to improve scaling resistance,

422 Bar Intake & Exhaust Valves S-Steel-422, Bar $ 7.56

446 Cr increased further to improve scaling 

resistance.

C.2.1.2 429 Slightly less Cr for better weldability

C.2.1.3 405 Lower Cr, Al added to prevent hardening 

when coiled from elevated temperatures.

C.2.1.4 409 Lower Cr, primarily used for automotive 

exhaust.

439 a higher grade version of 409. Increased 

chromium for improved high temperature 

corrosion/oxidation resistance.

Bar Direct Injection Components. S-Steel-439, Bar $ 3.00

439 a higher grade version of 409. Increased 

chromium for improved high temperature 

corrosion/oxidation resistance.

Tube Catalytic Converter Exhaust Sections, Direct 

Injection Components.

S-Steel-439, Tube $ 3.00

C.2.1.5 430F P&S added for improved machinability.

C.2.1.6 434 Mo added for improved corrosion 

resistance in auto trim.

436 Mo. & Cb added for corrosion & heat 

resistance & improved roping.

C3. 400 Series Martensitic Chromium Alloys Are hardenable through heat treatment. 

They are magnetic. The resistance 

corrosion in mild environments. They have 

fairly good ductility, and some can be heat 

treated to Tensile Strengths exceeding 

200kpsi. 

C3.1 410 General Purpose

C3.1.1 414 Ni Added for better corrosion resistance

Can not be hardened through heat treatment and only moderately hardened by cold working. The are magnetic, 

have good ductility and resistance to corrosion and oxidation. 
431 Cr increased, Ni added for corrosion 

resistance. Good mechanical properties.

422 Strength & toughness to 1200F via addition 

of Mi, V and W.

C3.1.2 403 Select quality for turbines and highly 

stressed parts.

C3.1.3 420 Increased C to improve mechanical 

properties.

C3.1.4 416 P & S increased to improve machining.

416SE Se added for better machine surface.

416 Bar Valves, Valve Seats S-Steel-416, Bar $ 1.41

C3.1.5 440C C increased for highest hardness. Cr 

increased for corrosion resistance.

Bar Intake & Exhaust Valves S-Steel-440C, Bar $ 4.56

440B C decreases slightly to improve toughness.

440A Same as 440B, only more so.

C4. 500 Series - Heat Resisting Chromium Alloys

C4.1 

C5.1 630 17Cr4Ni Bar Exhaust Valves S-Steel-630, Bar $ 2.17

C6. Duplex (Ferritic/Austenitic) Stainless Steels Have an annealed structure which is 

typically about equal parts of austenite and 

ferrite. Duplex stainless steels offer 

several advantages over 300 series: highly 

resistant to chloride stress corrosion 

cracking, have excellent pitting and crevice 

corrosi

C6.1 2205 Excellent corrosion resistance and high 

strength.

D. CAST IRONS

D1. Nodular/Ductile Cast Iron

Typical Cast Irons are 95%wt. Iron, 2.1-4%wt Carbon, and 1-3%wt. Silicon.

C5. 600 Series - Martensitic Precipitation 

Hardening Alloys

Chromium-Nickel Stainless types, some containing other alloying elements, such as copper or aluminum. They can 

be hardening by solution treating and aging to strength.

D1. Nodular/Ductile Cast Iron

Nodular / Ductile Iron (80-55-06) ASTM A536-80-55-06 $0.90-$1.2/lb finished 

casting

Crankshaft, blocks Nodular Iron, Cast $ 0.35

Nodular / Ductile Iron (100-70-03) ASTM A536-100-70-03 $0.90-$1.2/lb finished 

casting

High Strength Cam shafts i.e.., driving HP fuel 

pumps.

Nodular Iron, 

Gr100/70/03, Cast

$ 0.42

Ni-resist cast iron, D5S D5S, ASTM A-439-84 Housing - Turbo Exhaust NiResist Iron, D5S, 

Cast

$ 3.50

Ni-Resist cast iron, D5S D5S, ASTM A-439-84 $2.50/lb finished 

casting 

$1.26/lb without labor 

or scrap

Pumps, turbochargers $ 0.75

Silicon Molybdenum Cast Iron 4% Si & 1% Mo Housing-Block Center, Turbo Support SiMo Ductile Iron, Cast $ 0.60

D2. Malleable Cast Irons

Malleable Cast Iron $0.90-$1.2/lb finished 

casting

Crankshaft, camshafts, blocks Malleable Cast Iron $ 0.41

D3. Grey Cast Iron

Grey Cast Iron SAE J431 Grade 3000 (3.1-3.4C, 1.9-2.3Si, 

Mn 0.60-0.90)

Engine Blocks Grey Iron, Cast $ 0.35

D4. Austempered Ductile Iron

D5. Misc.

E. ALUMINUM ALLOYS 

E1. Wrought Alloys

E1.1 2XXX Al-Cu Alloys

2024 2024-T3/T4/T351 Bar Ø0.5-2.5" Aluminum-2024, Bar $ 2.38

2024 2024-T3/T4/T351 Sheet, 0.032"-0.125" Aluminum-2024, Sheet $ 3.41

E1.2 3XXX Al-Mn Alloys

(Temper Designations F>as Fabricated, O>annealed, H> Strain-hardened, W>Solution heat-treated. T> 

Thermally treated, usually solution heat-treated, quenched and precipitation hardened.
3003, 3005, 3012 Aluminum Magnesium Braze-clad welded radiator tubes, heater 

cores, radiator, heater and evaporative fins, 

heater inlet and outlet tubes, oil coolers, and 

air conditioner liquid lines, radiator heater and 

evaporative parts, extruded condenser tubes.

Aluminum-3000S, Coil $ 0.84

3003-H14 Uncladded Aluminum-Manganese Sheet Thick. 0.032-0.125" 

(0.75-3.15mm)

Heat Exchangers Aluminum-3003, Coil A $ 1.41

3003-H14 Uncladded Aluminum-Manganese Sheet Thick. 0.003-0.009" 

(0.075-0.22mm)

Heat Exchangers Aluminum-3003, Coil B $ 1.93

E1.3 4XXX Al-Si Alloys

4032 4032-T651 Bar Ø1.0-2.5" Aluminum-4032, Bar $ 1.44

AlSi Bar Spool valves AlSi13

E1.4 5XXX Al-Mg Alloys

5052H32 5052 H32 Coil 0.025-0.125" Aluminum-5052, Coil $ 1.52

E1.5 6XXX Al-Mg-Si Alloys

6062 6062-T6511 Bar Ø0.5-1.5" Spool valves Aluminum-6062, Bar $ 1.45

6061 6061-T6511 Bar Ø0.5-3.0" Aluminum-6061, Bar $ 1.50

6061 6061-T6511 Coil 0.25" Aluminum-6061, Coil 0-

0.025"

$ 2.83

6061 6061-T6511 Coil 0.32-0.125" Aluminum-6061, Coil 

0.032-0.125"

$ 1.93

E1.6 7XXX Al-Zn Alloys

7075-T6 Forgings and Extrusions Aluminum-7075-T6, Ext. $ 3.21

7075 7075-T651 Bar 1.0-1.75" Aluminum-7075, Bar $ 2.82

E1.7 8XXX Al+Other Elements

E1.8 Misc

3003-H14 Clad 4XXX Aluminum-Manganese Cladded Tube Seamless welded tube 

- thickness 0.012-0.02" 

(0.3-0.5mm)

Heat Exchangers Cladded Aluminum3003, Tube$ 2.28

E2. Casting Alloys ( Hypoeutectic 8.5-10.5, Eutectic 11-12, 16-18 Hypereutectic Material )

2XX Al-Cu Alloys

3XX Al-Si + Cu and/or Mg Alloys

319 T5 Al-3.5Cu-6Si Hypoeutectic/Perm. Manifolds, cylinder heads, blocks, internal 

engine parts

Aluminum-A319-T5, Cast$ 1.15

332 / F132 8.5-10Si, 2.0-4.0Cu, Ni0.10 Hypereutectic, 

common grade, large 

recycled composition 

(Die.)

Hypoeutectic Aluminum-332, Cast $ 1.24

356 T6 or A356 7Si-0.3 Mg alloy Hypoeutectic (Perm.) Engine blocks, flywheel, oil pan, pump bodies, 

cyl heads, manifolds, transmission cases

Aluminum-356-T6, Cast $ 1.20

A380.1 Al-9Si-3Cu(Fe) Hypoeutectic (Die.) Blocks, transmission housings/parts, fuel 

metering devices, oil pump cyl heads, 

Aluminum-A380, Cast $ 1.10

B380 Al-9Si-3Cu(Fe) Hypoeutectic (Die) Blocks, transmission housings/parts, fuel 

metering devices, oil pump cyl heads, 

Aluminum-B380, Cast $ 1.18

384 Eutectic (Die) Pistons, automatic transmissions Aluminum-384, Cast $ 1.14

B390.0 Hypereutectic aluminum-silicon Hypereutectic (Die.) High-wear applications such as ring gears and 

internal transmission parts, Hypereutectic 

pistons, cylinder blocks

Aluminum-B390, Cast $ 1.20

A383 AlSi10Cu2 Hypoeutectic (Die.) Blocks 

3HA Piston Alloy AlSi12Cu4Ni2Mg

4XX Al-Si Alloys

A413 AlSi13 AlSi.13 $ 1.14

5XX Al-Mg Alloys

7XX Al-Zn Alloys

8XX Al-Sn

9XX Al + Other Elements

F. POWDER METALS (Classification per MPIF Standard 35)

F1. PM Structural Materials: Ferrous and Non-ferrous Crank timing sprockets or gears, cam shaft 

timing sprocket or gears, Transmission clutch 

hubs, ATM planetary ring gear, Cam lobe on 

composite cam shaft, impellers.

Ferrous Materials

F1.1 Iron and Carbons Steel

Sintered Powdered Metal (Iron 

base powder alloy)

SAE 1541 PM-SMF-Iron Base $ 1.00

Carbon Steel F-0008, 0.8C

F-0008-HT

ρ=6.9g/cm^3,UTS=54k

si

ρ=6.9g/cm^3,UTS=85k

si

Cost Effective

F1.2 Iron-Copper and Copper Steel
Copper Steel FC-0208, 2Cu, 0.8C

FC-0208-HT

ρ=6.7g/cm^3,UTS=60k

si

ρ=6.7g/cm^3,UTS=85k

si

Good sintered strength PM-SMF-FC0208 $ 1.00

F1.3 Diffusion-Alloyed Steel

Diffusion Alloyed Steel FD-0205, 1.75Ni, 1.5Cu, 0.5Mo, 0.5C

F-0008-HT

ρ=6.95g/cm^3,UTS=78

ksi

ρ=6.95g/cm^3,UTS=13

0ksi

Best sintered strength

F1.4 Prealloyed Steel

Low Alloy Steel FL-4405,0.85Mo,0.5C

FL-4405-HT

ρ=7.1g/cm^3,UTS=66k

si

ρ=7.1g/cm^3,UTS=160

ksi

Good Hardenability, consistency in heat 

treatment

F1.5 Sinter Hardened Steel

Sinter Hardened Steel FLC-4608-HT, 1.75Ni, 1.5Cu, 0.5Mo, 0.8C ρ=7.0g/cm^3,UTS=100

ksi

Hardenable in sintering.

F1.6 Hybrid Low-Alloy Steel Valve Seat Inserts

Hybrid Low-Alloy Steel FLN-4405, 2Ni, 0.85Mo,0.5C

FLN-4405-HT

ρ=7.05g/cm^3,UTS=80

ksi

ρ=7.05g/cm^3,UTS=17

0ksi

Best heat-treated impact strength, impact 

energy

F1.7 Iron-Nickel and Nickel Steel

Nickel Steel FN-0205, 2Ni, 0.5C

FN-0205-HT

ρ=7.1g/cm^3,UTS=57k

si

ρ=7.1g/cm^3,UTS=145

ksi

Good heat-treated strength, impact energy PM-SMF-FN0205 $ 2.00

F1.8 Soft-Magnetic Alloys

Iron Magnets FF-0000, <0.03C ρ=6.6-7.2g/cm^3, 

Ind.=9-12kG. Coercive 

Field =2.1 Oersted, 

Permeability =1700-

2700

Magnetic Properties @ 15Oe

Phosphorous Iron Magnets FY-4500 0.45P ρ=6.8-7.2g/cm^3, 

Ind.=10.5-12.5kG. 

Coercive Field =1.8 

Oersted, Permeability 

=2300-2700

Soft magnetic cores for electric motors

Silicon Iron Magnets FS-0300, 3si ρ=7.2g/cm^3, 

Ind.=13.0kG. Coercive 

Field =1.0 Oersted, 

Permeability =5000

Soft magnetic cores for electric motors, 

transformers

Nickel Iron Magnets FN-5000, 3si ρ=7.5g/cm^3, Electronic Components such as switching 

Ind.=12.0kG. Coercive 

Field =0.3 Oersted, 

Permeability =12,000

Electronic Components such as switching 

regulator inductors, in-line noise filters, and 

pulse and fly-back transformer applications

F1.9 Copper-Infiltrated Iron and Steel

F1.10 Stainless Steel - 300 Series Alloy

304/304L PM-SMF-SS304 $ 4.92

316 Stainless SS-316N2, 17Cr,12Ni,2.5Mo ρ=6.5g/cm^3,UTS=60k

si

Good Corrosion Resistance, Appearance PM-SMF-SS316 $ 8.16

F1.11 Stainless Steel - 400 Series Alloy

430 Stainless SS-430N2, 17Cr ρ=7.1g/cm^3,UTS=60k

si

Good Corrosion Resistance, Appearance

410 Stainless SS-41, 13Cr, 0.8Si, 0.8Mn

ρ=6.1g/cm^3,UTS=66.

7ksi DI Solenoids PM-SMF-SS410

$ 4.50

F1.12 Miscellaneous

Non-Ferrous Materials

F1.20 Copper and Copper Alloys

Copper, C-0000, 0.2Max Other

ρ=8.0g/cm^3, 

85%IACS Electrical parts

F1.21 Aluminum and Aluminum Alloys

PM Aluminum - Structural 

Components 4Cu, 0.5Mg, 1Si

ρ=2.6g/cm^3. UTS =32 

ksi (T4 Heat Treat)

Light weight, corrosion resistance, good 

electrical and thermal conductivity. Cam Caps

PM Aluminum - Structural 

Components 4.4Cu/0.5Mg/0.6Si

Ys/UTS in ksi: w. T4 

HT, 31/38 w. T6 HT 

47.5/48.1

Cam Caps PM-SMNF-Aluminum $ 3.50 

F1.22 Bronze Alloys

F1.23 Brass Alloys

Red Brass CZ-1000, 10Zn

ρ=7.9 

g/cm^3,Ys=11ksi Hardware items

Yellow Brass CZ-3000, 30Zn

ρ=7.6 

g/cm^3,Ys=16ksi Hardware items

F1.24 Nickel Silver Alloys

Nickel Silver CNZ-1818, 18Ni,18Zn

ρ=7.9 

g/cm^3,Ys=20ksi Appearance, Corrosion Resistance,

F1.25 Titanium Alloys

Titanium Powder (3x Ingot Price) $ 63.90

Titanium -Aluminide Alloy 

Powder Ti 47A1 4 Turbocharger, Valves

$ 4.59
F2. P/F Steel Part Materials

F2.0 Carbon Steel

Powdered forged FC-0305, FC-0308 both with MnS 3Cu5C, 3Cu6C, 

3Cu7C Connecting Rods $ 1.00

Powdered forged PFeCu3 or Cu2 PFeCu3 or Cu2 Connecting Rods

Powdered forged HS150/160 Connecting Rods PF-SMF-HS150/160 $ 0.70

F3. P/M Self-Lubricating Bearing Materials

F3.0 Diluted Bronze Bearings

F3.1 Bronze Bearings

Bronze (Copper Tin) CT-1000

ρ=6-6.4g/cm^3, K 

Strength = 19 ksi Self Lubricating Bearings, 24% Oil Content

Bronze (Copper, Tin10%, 1% 

Graphite) CTG-1001

ρ=6.4-6.8g/cm^3, K 

Strength = 23 ksi Self Lubricating Bearings, 17% Oil Content

Diluted Bronze FCTG-3604

ρ=6-6.4g/cm^3, K 

Strength = 22 ksi Self Lubricating Bearings, 17% Oil Content

F3.2 Iron and Iron-Carbon Bearings

F3.3 Iron-Copper Bearings

F3.4 Iron-Copper-Carbon Bearings

F3.5 Iron-Graphite Bearings

Iron Graphite FG-0303

ρ=5.6-6.0g/cm^3, K 

Strength = 10 ksi Self Lubricating Bearings, 18% Oil Content

F4. Metal Injection Molded Materials

F4.0 Stainless Steels

Austenitic Stainless MIM-304 L

ρ=7.7g/cm^3, Ys=25, 

Elong=30%, 65 HRB

Austenitic Stainless MIM-316L

ρ=7.7g/cm^3, Ys=25, 

Elong=30%, 65 HRB turbocharger rotors

Ferritic Stainless MIM-430

ρ=7.5g/cm^3, Ys=35, 

Elong=30%, 65 HRB

Martensitic Stainless MIM-420 (Premium)

ρ=7.6g/cm^3, Ys=240, 

Elong=8%, 52HRC

Martensitic Stainless MIM-440C(Premium)

ρ=7.5g/cm^3, Ys=195, 

Elong=4%, 59 HRC

S-Steel-440-MIM $ 13.68

Precipitation Hardening 

Stainless MIM-17-4-PH H900

ρ=7.6g/cm^3, Ys=160, 

Elong=7%,36 HRC

Duplex Structure Stainless MIM-318

ρ=7.5g/cm^3, Ys=75, 

Elong=27%,93 HRB

F4.1 Low-Alloy Steels

Low Alloys Steels MIM-2700 ??

ρ=7.6g/cm^3, Ys=37, 

Elong=26%,69 HRB

Nickel Molybdenum Steel

MIM-4605

MIM-4605-HT

ρ=7.5g/cm^3, 

Ys=30ksi, Elong=15%, 

62 HRB

p=7.5g/cm^3, 

Ys=215ksi, Elong=2%, 

48HRC

F4.2 Soft Magnetic Alloys

Soft-Magnetic Alloys MIM-2200 ??

ρ=7.6g/cm^3, 

Ind.=8kG. Coercive 

Field =1.5Oersted, 

Permeability =2300

Silicon Based Soft Magnetic 

Alloy, Grade 1 MIM-Fe3%, Si

ρ=7.6g/cm^3, 

Ind.=12kG. Coercive 

Field =0.7Oersted, 

Permeability =8500

Cobalt Based Soft Magnetic 

Alloy MIM-Fe-50%Co

ρ=7.7g/cm^3, 

Ind.=14kG. Coercive 

Field =1.5Oersted, 

Permeability =5200

Nickel Based Soft Magnetic 

Alloy, 

Grade 1 MIM-Fe-50%Ni

ρ=7.7g/cm^3, 

Ind.=10kG. Coercive 

Field =0.13 Oersted, 

Permeability =47,500

F4.3 Controlled-Expansion Alloys

Controlled Expansion MIM-F-15??

F5. Miscellaneous

G. MAGNESIUM WROUGHT & CASTING ALLOYS

G1. Wrought Alloys

XXXX Alloys

G2. Cast Alloys

AZ91

AZ91 AZ91D Mg Al9 Zn1 Valve Covers Magnesium-AZ91D, 

Cast $ 2.42

H. TITANIUM WROUGHT & CASTING ALLOYS

H1. Wrought Alloys

Titanium Titanium (Sponge Only) (Sponge Only) Titanium Titanium-Sponge, Cast -Sponge, Cast $ $ 4.71

Titanium (6AL V4) Bar High Pressure Bellows Pump Titanium-6AL4V, Bar $ 34.37
Titanium (6AL V4) Plate Titanium-6AL4V, Plate $ 43.91

H2. Cast Alloys

Titanium (6AL V4) Ingot Titanium-6AL4V, Cast $ 21.30

J. COPPER WROUGHT & CASTING ALLOYS (BRONZE & BRASS)

J6.1 Lead Red Brasses )(LC-M, T=M, C/E=L RS=L, H/W=G)

C83600 (115) Leaded Red Brass 85-5-5-5 Pump Components, Small Gears, Water 

Impellers, Housings, Marine Fittings, Flanges

C84400 (123) Semi Lead Red Brass 81-3-7-9 Alloy Mainly used in the manufacture of 

aerospace, automotive and other industrial 

sectors to bear the friction parts, such as 

cylinder piston pin bushings, bearings and 

bushings of the liner, connecting rod, vice 

bush, and the disc washer

J6.2 Tin Bronzes (LC-H, T=H, C/E=M RS=M, H/W=H)

J6.3 High Lead Tin Bronze & Lead Free Bronze (LC-M/H, T=H, C/E=G RS=G, H/W=H)

C93200 SAE 660 Bearing Bronze bushings, pump fixtures, pump impellers, fuel 

pump bushings, thrust washers, insert 

bearings, gears, valves and valve 

components, etc.

Bronze-932, Bar $ 2.56

C93200 SAE 660 Bearing Bronze, 1" round bar, 

Bronze-932, Bar, 

1" Round Bar bushings, pump fixtures, pump impellers, fuel 

pump bushings, thrust washers, insert 

bearings, gears, valves and valve 

components, etc.

Bronze-932, Bar Ø1" $ 4.40

C89320 Lead Free Replacement to C93200 89%Cu, 6%Sn, and 

5%Bi

Turbocharger Spindle Bushings (Floating 

Type)

Bronze-89320, Bar $ 2.56

Oilite Bronze Bearing Alloy SAE841 1" Round Bar $ 5.31

J6.4 Aluminum Bronze(LC-VH, T=VH, C/E=P RS=M, H/W=VH)

C95400 bushings, hydraulic valve parts, pump rods, 

guide pin bushings, bearings, wear plates, 

screw nuts, gear wheels, worm gears, spur 

gears, valve guides, high strength clamps, 

pressure blocks, machine parts, etc.

C95800 (415G) Aluminum Bronze 81-5-4-9-1Mn Nuts, Shafts, Machinery, Valve Bodies, 

Propeller Hub, Worm Wheels, Propeller 

Blades, Worms, Wear Plates, Gears, Bushings

ASTM C63000, C63020 Nickel Aluminum Bronze Valve stems and trim, bearings and bushings, 

fasteners, gears

Ni-Al-Bronze-630000, 

Bar

$ 2.44

ASTM C63000, C63020 Nickel Aluminum Bronze 1" Round Bar Valve stems and trim, bearings and bushings, 

fasteners, gears

$ 9.68

J6.5 High Strength Brasses (LC=M , T=M , C/E=P , RS=M , H/W=H )

J6.6 Copper Beryllium Alloys (LC=H , T=H , C/E=P , RS=P , H/W=VH )

J6.7Leaded Coppers (LC=M , T=H , C/E=VG , RS=VG , H/W=M )

J6.8 Tin Based Babbits (LC=M, T=M , C/E=E , RS=E , H/W=L )

J6.9 Lead Base Babbits (LC=M , T=M , C/E=E , RS=E, H/W=L )

J6.10 Aluminum Low-Tin or Leaded Alloys (LC=H , T=H , C/E=G , RS=L, H/W=M )

J6.11 Aluminum High-Tin or Leaded Alloys (LC=M , T=H , C/E=G , RS=M, H/W=M )

J6.12 Silicon Brasses (LC=? , T=? , C/E=? , RS=?, H/W=?)

C87500 (500) Silicon Brass, 82-4Si-14Zn Bearings, gears, impellers, rocker arms, valve 

stems, brush holders, bearing races, small 

boat propellers.

Si-Brass-87500, Bar $ 2.11

C87500 (500) Silicon Brass, 82-4Si-14Zn Ingot $ 2.89

CDA 673 - Silicon Manganese 

Brass

C67300 Bar Si-Brass-67300, Bar $ 3.71

CDA 675 - Manganese Bronze C67500 Bar Si-Brass-67500, Bar $ 6.90

J6.13 Yellow Brasses (LC=? , T=? , C/E=? , RS=?, H/W=?)

C85400 (403) Yellow Brass 67-1-3-29 Electrical Connectors, Radiator Cores, Tanks, 

Heater Cores, Radiator Tanks, Odometer 

Contacts, Thermostats, Radiator Tube

J6.13 Brass General 

C36000 CDA 360 Fluid connectors, threaded inserts for plastic 

parts, sensor bodies, thermostat parts

Brass-36000, Bar $ 1.70

C36000 CDA 360 1" Round Bar Fluid connectors, threaded inserts for 

plastic parts, sensor bodies, thermostat 

parts

Brass-36000, Bar, Ø1" $ 5.54

J6.14 Copper General 

Copper >99.0% Pure Wire harnesses Copper-Pure, Wire $ 2.45
K. NICKEL WROUGHT & CASTING ALLOYS

K1. Wrought Alloys

K1.1 Inconel®

Inconel® 751/HEV3 Bar Exhaust Valves Inconel-751, Bar $ 12.22

Inconel® 713 Coil Coil Heat Shields, Turbo Inconel-713C, Coil $ 6.00

Nickel Alloy - Internal Turbo Parts General Coil Heat Shields, Turbo Nickel Alloy Gen, Cast $ 5.00

Inconel® 713 Coil Cast Inconel-713, Cast $ 6.00

Nickel Based Alloy Inconel 718 1" Round Bar Inconel-718, Bar $ 20.26

K2. Cast Alloys

XXXX Alloys

L. COBALT WROUGHT & CASTING ALLOYS

L1. Wrought Alloys

L1.1 Stellite®

Stellite® 6 Base Co, Cr 27-32%, W4-6%, C0.9-1.4%, 

Others Ni, Fe, Si, Mn, Mo

Bar Exhaust Valves Stellite $ 21.00

L2. Cast Alloys

XXXX Alloys

M. OPEN FOR METAL ALLOYS

N. OPEN FOR METAL ALLOYS

O. OPEN FOR METAL ALLOYS

P. OPEN FOR METAL ALLOYS

Q. THERMOPLASTIC POLYMNERS

Q1. Polyamide (PA/Nylon)

Nylon 6 PA6 Nylon6, Inject. $ 1.65

Nylon 6 (15 % glass) PA6 GF15 Air cooler tube outlet Nylon6-15GF, Inject. $ 1.59

Nylon 6 (30 to 35% glass) PA6 GF30 Vacuum reservoir, Intake manifold Nylon6-30GF, Inject. $ 1.76

Nylon 66 PA66 Fuel injector connector, hose asm end - pump 

to turbo, chain tension guides

Nylon66, Inject. $ 1.74

Nylon 66 (30 to 35% glass) PA66 GF30 Intake manifold, cylinder cover, cooler asm 

end caps

Nylon66-30GF, Inject. $ 1.54

Nylon 66 (50% glass) PA66 GF50 cooler asm end caps Nylon66-50GF, Inject. $ 1.54

Nylon 66, 40% Fibrous Mineral 

Reinforced

PA66 FMR40% GMNA Spec PA66 060 Direct Injection Connectors Nylon66-40FMR, Inject. $ 1.54

Nylon 12 PA12 Reservior tube Nylon12, Inject. $ 3.03

Nylon 12, 30% glass PA12, GF30 PCV Hose Intake End $ 3.41

High Temp Polyimide (Semiaromatic Polyimide) Zytel HTN51 DuPont Material 

1.31g/cm^3 Engine Seals Nylon-HT, Inject. $ 4.00

Q2. Polyacetal (POM/Acetal)

Q3. Polyethylene

HDPE Copolymer - blowmolding HDPE Rubberized blow molded air induction ducts 

and couplings. HDPE BM Grade $ 0.72

Q4. Polybutylene Terephthalate (PBT)

Polybutylene Terephthalate PBT GF20 Silencer Air by-pass PBT-GF20, Inject. $ 1.46

Q5. Acrylonitrile Butadiene Styrene (ABS)

ABS Beta patch for battery closeout $ 0.72

Q6. Polypropylene (PP)

PP Homopolymer w. 40% Talc. 

Filler

PP-TD40 Cooling Fan Shroud

Random copolymer blow molding 

grade.

PP High strength blow molded air induction ducts. HD Polypro $ 0.87

Q7. Fluroplastic (PTFE, FEP, PFA, etc)

Q8. Polyphenylene Sulfide (PPS)

Polyphenylene Sulfide 35%GF, 

30%Filler

PPS GF35%, MF30% Auxiliary water pump housing PPS-GF35-MF30, Inject.$ 3.86

Polyphenylene Sulfide 40%GF PPS GF40% Auxiliary water pump housing PPS-GF40, Inject. $ 6.02

Q9. Polyvinylchloride (PVC)

Blended NBR-PVC Rubberized blow molded air induction ducts 

and couplings.

NBR-PVC $ 1.27
Q9. Miscellaneous

Teflon® Polytetrafluoroethylene PTFE, Inject. $ 6.70

R. THERMOSET POLYMERS

R1 Hydrocarbon, Unsaturated.

Natural rubber / TSR20 NR Hoses, O-rings, gaskets, tubes Thermoset-NR $ 2.14

Synthetic poly-isoprene rubber IR Hoses, O-rings, gaskets, tubes Thermoset-IR

Styrene butadiene rubber SBR Hoses, O-rings, gaskets, tubes Thermoset-SBR $ 1.32

Butadiene rubber BR Hoses, O-rings, gaskets, tubes Thermoset-BR $ 0.65

Polubutadiene rubber PBR Hoses, O-rings, gaskets, tubes Thermoset-PBR $ 0.82

Polubutadiene rubber - glass 

filled

PBR GF20 Auxiliary water pump housing Thermoset-PBR-GF20 $ 1.17

Butyl rubber IIR Hoses, O-rings, gaskets, tubes Thermoset-IIR $ 1.37

Chloro- and bromo- butyl rubber CIIR, BIIR Hoses, O-rings, gaskets, tubes

R2. Hydrocarbon Saturated

Ethylene propylene (diene) 

rubber

EPM/EPDM Hoses, O-rings, gaskets, tubes Thermoset-EPDM $ 1.83

R3. Nitrile

Nitrile butadiene rubber NBR Hoses, O-rings, gaskets, tubes Thermoset-NBR $ 1.27

Hydrogenated nitrile rubber HNBR Hoses, O-rings, gaskets, tubes

Carboxylated nitrile rubber XNBR Hoses, O-rings, gaskets, tubes

Nitrile-PVC blend NBR+PVC Hoses, O-rings, gaskets, tubes

R4. Chlorocarbon, Unsaturated.

Polychloroprene rubber CR Hoses, O-rings, gaskets, tubes

R5. Chlorocarbon, Unsaturated.

Chloro-sulfonated polyethylene CSM Hoses, O-rings, gaskets, tubes

Chlorinated polyethylene CM Hoses, O-rings, gaskets, tubes

R6. Acrylate

Acrylic rubber ACM Hoses, O-rings, gaskets, tubes

Ethylene acrylic copolymer 

rubber

AEM Hoses, O-rings, gaskets, tubes

R7. Vinyl Acetate

Ethylene vinyl acetate copolymer 

rubber

EVM Hoses, O-rings, gaskets, tubes

R8. Fluorocarbon

Fluoro elastomer FKM ERG valve seals Thermoset-FKM $ 12.50

Perfluoro elastomer FFKM Hoses, O-rings, gaskets, tubes

Tetrafluoroethylene propylene 

elastomer

FEPM Hoses, O-rings, gaskets, tubes

R9. Polysulfide.

Polysulfide rubber TM Hoses, O-rings, gaskets, tubes

R10. Polyimide

Polyimide - Vespel SP-21 PI 30%Carbon filled thrust washers, bearings and seals — lowfriction properties, work with or without 

lubrication.

Thermoset-Vespel 

SP21CF30

$ 35.18

Polyimide - Vespel SP-21 PI 30%Glass filled Thermoset-Vespel 

SP21GF30

$ 24.36

R11. Polyether

Epichorohydrin rubber CO/ECO Hoses, O-rings, gaskets, tubes

Polypropylene oxide rubber GPO Hoses, O-rings, gaskets, tubes

R12. Polyurethane

Polyurethane elastomer, esterbasedAU Hoses, O-rings, gaskets, tubes Thermoset-AU $ 1.77

Polyurethane elastomer, etherbasedEU Hoses, O-rings, gaskets, tubes

R13. Silicone

Silicone rubber MVQ Hoses, O-rings, gaskets, tubes Thermoset-MVQ $ 4.50

Phenyl methyl silicone rubber PMVQ Hoses, O-rings, gaskets, tubes

Fluoro silicone rubber FMVQ Hoses, O-rings, gaskets, tubes

R14. Miscellaneous

SBR Tubing w. Fiber 

Reinforcement

SBR Reinforced Tubing SBR-Fiber Rein., 

Extruded

$ 1.85

SBR Tubing w. Metal 

Reinforcement

SBR Reinforced Tubing SBR-Metal Rein., 

Extruded

$ 2.24

SBR Tubing w. Fiber 

Reinforcement and outer wrap.

SBR Reinforced Tubing SBR-Fiber Rein. W. 

Outer Wrap, Extruded

$ 2.05

S. THERMOPLASTIC ELASTOMERS

Olefinic Syn Rubber M-group Synthetic Hoses, O-rings, gaskets, tubes TPE-PP/EPDM, Inject. $ 0.99

Olefinic TPE+TD33 Cooling Fan Shroud $ 1.04

T. Open for Plastics
U. AUTOMOTIVE FLUIDS

Engine Oil - Synthetic (Price/Quart) Engine Oil-Synthetic $ 1.40

Engine Oil - Regular (Price/Quart) Engine Oil-Regular $ 0.60

V. PLATINGS & COATINGS

V.1 Aluminum Cladding

Aluminum-Silicon Cladding 3003 Sheet w. 4047 Cladding 

Single Cladding, Combined Material 

Thickness <0.060" 

Thickness tolerance 

10% Base Material 

Thickness

Oil Coolers, Radiators, etc Aluminum3003/4047A, Cladding

$ 1.65

Aluminum-Silicon Cladding 3003 Sheet w. 4047 Cladding 

Single Cladding, Combined Material 

Thickness >0.060" 

Thickness tolerance 

10% Base Material 

Thickness

Oil Coolers, Radiators, etc Aluminum3003/4047B, Cladding

$ 2.10

Brazing Compound Brazing Compound-AC $ 20.00

Brake and Oil Line Platings GALFAN Hot Dipped Thickness 4mil or 0.1 

mm

GALFAN $ 0.56

V.2 Hot Dip Galanizing

V.3. Electroplating/E-Coat

Fuel Rail Plating Plating, Fuel Rail $ 20.00

General Engine Coating General Underhood 

Plating

$ 15.00

Zinc Electroplate Zinc Electroplate $ 5.00

V.4. Electroless

V.5 Powder Coating

General Powder Coat 96 Hour Salt Spray Powder Coat $ 20.00

V.6 Phosphate Coating

V.7 Anodizing 1.61756E-07

V.8 Anti Friction Coatings

High Temperature, Anit Friction 

Coatings

Sandstrom Coatings, Series E724 Density = 2.906E-6 

lbs/mm^3

Piston Skirts High Temp, Anti 

Friction, Molybdenum 

Coatings 

$ 250.00

High Temperature, Anit Friction 

Coatings

Everlube 6108, PTFE, Solid Film 

Lubricants

1006gram/liter

(8.4llbs/gal)

High speed and temp anti friction material. High Temp, Anti 

Friction, PTFE 

$ 178.57

Coatings Lubricants

(Covers 51.93E6mm^2/3.78 liters @ 17.6 

Microns)

(1.618E-07 lbs/mm^2)

(8.4llbs/gal) Friction, PTFE 

Coating 

V.8 Anti Friction Coatings

WC2 Spray Clutch Forks WC2, Spray $ 250.00

W. MISC

Not Applicable Not Applicable $ -

Purchase Parts Purchased Parts $ 1.00

Nylon Protective Sheathing (Price/in2

) Nylon Protective 

Sheathing

$ 0.01

Sand Cores Sand of Cores $ 0.16

Copper Cladded Steel Copper Clad Steel $ 1.50

1 Metal Laminate Steel Metal, Viscoelastic Polymer Core, Approx. 

< 1 mm Thick

Metal Laminate, Type 

A, < 1.0

$ 0.80

2 Acrylic Powder Coat Acrylic Powder Coat Acrylic Powder Coat $ 20.00

http://www.specialchem4coatings.com/tc/po

wder-coatings/index.aspx?id=resin

3 Silicon Electrical Steel (Need more info on pulled from article Si. Elect. Steel $ 0.75

4 Aromatic Polymide Film AKA Aramid Aramid

5 Vanish Copper Copper Wire, Varnished Motor Windings Copper - Windings, 

<1mm

$ 2.94

6 High Voltage Cable Cost 600V, 100-120Amp Twisted Pair, Braided 

Sheathing

$5/ft

7 Electronics Grade Silicone GE Silicone, RTV 162-GE RTV Silicone 

Adhesive Sealant, Electronics Grade

$35/kg

Price $981.56/22.4Kg Discount additional 

20% for study value
(Density = 1.3E-6Kg/mm^3

8 Potting Gel Dow Corning Potting Gel 3-4680 $27/kg

Price $1213/36 Kg Discount additional 20% 

for study value

Density 9.7E-7 Kg/mm^3

9 High Temp Silicone

10 Zinc Zamak #2 (Kirksite) High copper content (3%) 

results in property changes 

upon long term aging. 

These changes include 

slight dimensional growth 

(0.0014 in/in/after 20 yrs.), 

lower elongation and 

reduced impact 

performance (to levels 

similar to aluminum alloys) 

for die cast products.

No. 2 is the only ZAMAK alloy which is used for gravity 

casting; mainly for metal forming dies or plastic injection 

tools. This alloy is sometimes referred to as Kirksite. For die 

casting, No. 2 offers the highest strength and hardness of 

the ZAMAK family. 

Although No. 2 alloy exhibits excellent castability, it has seen 

limited use by die casters in North America. It does, 

however, provide some interesting characteristics which 

may assist designers. Its creep performance is rated higher 

than the other ZAMAKs and No. 2 maintains higher strength 

and hardness levels after long term aging. Also, preliminary 

investigations suggest No. 2 alloy is a good bearing material, 

and may eliminate bushings and wear inserts in die cast 

designs.

Zinc Zmk#2 $ 1.74

Zamak #3

No. 3 alloy is usually 1st when considering zinc die 

casting. Its excellent balance of desirable physical 

and mechanical properties, superb castability and 

long-term dimensional stability are the reasons 

why over 70% of all North American zinc die 

castings are in No. 3 alloy. It is, therefore, the 

most widely available alloy from die casting 

sources. ZAMAK No. 3 also offers excellent 

finishing characteristics for plating, painting and 

chromate treatments. It is the "standard" by which 

other zinc alloys are rated in terms of die casting.

Zinc Zmk#3 $ 1.24

Zamak #5 Contains an addition of 1%

copper over #3 which 

accounts for these property 

changes.

No. 5 alloy castings are marginally stronger and harder than 

No. 3. However, these improvements are tempered with a 

reduction in ductility which can affect formability during 

secondary bending, riveting, swaging or crimping operations. 

The alloy is widely die cast in Europe and does exhibit 

excellent castability characteristics, as well as, improved 

creep performance over No. 3.

Because of No. 3's wide availability, material specifiers often 

strengthen components by design modifications instead of 

using No. 5. However, when an extra measure of tensile 

performance is needed, No. 5 alloy castings are 

recommended. The alloy is readily plated, finished and 

machined, comparable to No. 3 alloy.

Zinc Zmk#5 $ 1.49

Zamak #7 No. 7 alloy is a modification 

of #3 alloy in which lower 

magnesium content is 

specified in order to increase 

the fluidity. To avoid 

problems with inter-granular 

corrosion lower levels of 

impurities are called for and a 

small quantity of nickel is 

specified. Alloy #7 has slightly 

better ductility than #3 with 

other properties remaining at 

the same level. 

The alloy is therefore popular for those special cases where 

the die caster is making thin walled components requiring a 

good surface finish. However, research testing has shown 

that metal and die temperatures have a bigger effect than 

changing alloys. Close attention to control of the die casting 

process parameters is important so as to eliminate defects 

and achieve consistent quality.

Zinc Zmk#7 $ 1.61

ZA-8 A good gravity casting alloy, ZA-8 is rapidly growing for 

pressure die casting. ZA-8 can be hot chamber die cast, 

with improved strength, hardness and creep properties over 

ZAMAK's, with the exception of a No. 2 alloy which is very 

similar in performance. ZA-8 is readily plated and finished 

using standard procedures for ZAMAK. When the 

performance of standard No. 3 or No. 5 is in question, ZA-8 

is often the die casting choice because of high strength and 

creep properties and efficient hot chamber castability.

ZA-8

ZA-12 ZA-12 is the most versatile zinc alloy in terms of combining 

high performance properties and ease of fabrication using 

either gravity or pressure die casting. ZA-12 is the best 

gravity casting alloy for sand, permanent mold and the new 

graphite mold casting process. It is also a good pressure die 

casting alloy (cold chamber) which provides a sounder 

structure than ZA-27, as well as higher die cast elongation 

and impact properties. For these reasons, die cast ZA-12 

often competes with ZA-27 for strength application. An 

excellent bearing alloy, ZA-12 is also platable, although 

plating adhesion is reduced compared to the ZAMAK alloys.

ZA-12

ZA-27 ZA-27 is the high strength performer of the zinc alloys 

whether for gravity or pressure die casting (cold chamber). It 

is also the lightest alloy and offers excellent bearing and 

wear resistance properties. ZA-27, however, requires care 

during melting and casting to assure sound internal 

structure, particularly for heavy wall sections. It may also 

need a stabilization heat treatment when tight dimensional 

tolerances are required. ZA-27 is not recommended for 

plating. However, when brute strength or wear resistant 

properties are needed, ZA-27 has demonstrated 

extraordinary performance.

ZA-27
Notes

1. Material composition analysis was used when published data on specific materials was not available. Materials in related categories with similar compositions and established price points were compared to the mat

investigation. Elemental compositions were then compared and deltas defined to determine cost differences. Since the cost differences are calculated from the elemental deltas, it was necessary to obtain the cost of th

elements. The costs of base elements such as zinc, copper and magnesium are readily available and published in several websites. Next, the cost per pound for each element that varied was multiplied by the delta pe

difference. These incremental elemental cost differences (plus/minus) were added to the base price point to establish a price per pound of the material under investigation. Lastly the surcharge was added to the cost to 

final alloy price per pound. A surcharge is a special charge to cover unexpected or temporary costs in the production of alloys. Surcharges are also posted on various manufacturers websites to alert their customers of 

price fluctuations. 
2008 2015 2020

$ - NA $ 0.45 ≥9M $ - NA $ 0.48 ≥9M $ - NA $ 0.51

$ - NA $ 0.55 ≥9M $ - NA $ 0.59 ≥9M $ - NA $ 0.61

$ - NA $ 0.65 ≥9M $ - NA $ 0.65 ≥9M $ - NA $ 0.65

$ - NA $ 0.65 ≥9M $ - NA $ 0.65 ≥9M $ - NA $ 0.65

$ - NA $ 0.48 $ - NA $ - $ - NA $ -

$ - NA $ 0.74 ≥9M $ - NA $ 0.78 ≥9M $ - NA $ 0.80

$ - NA $ 0.80 ≥9M $ - NA $ 0.84 ≥9M $ - NA $ 0.86

$ - NA $ 0.62 ≥9M $ - NA $ 0.66 ≥9M $ - NA $ 0.68

$ - NA $ 0.62 ≥9M $ - NA $ 0.66 ≥9M $ - NA $ 0.68

$ - NA $ 0.62 ≥9M $ - NA $ 0.62 ≥9M $ - NA $ 0.62

Price/lb

Production Year: Production Year: Production Year:

Low Annual 

Consumption 

Rate 

Low Annual 

Consumption 

Rate 

Price/lb Price/lb

High Annual 

Consumption 

Rate 

Price/lb Price/lb

Low Annual 

Consumption 

Rate 

Price/lb

High Annual 

Consumption 

Rate 

Yellow = Sue new Price, what do we use?

Purple = Need Price, Talk with Purchasing

Red = Sue had Red 

Orange = Pricing appears incorrect.

$ - NA $ 0.78 ≥9M $ - NA $ 0.81 ≥9M $ - NA $ 0.83

$ - NA $ 0.98 ≥9M $ - NA $ 1.02 ≥9M $ - NA $ 1.04

$ - NA $ 6.65 ≥9M $ - NA $ - ≥9M $ - NA $ -

$ - NA $ 0.74 ≥9M $ - NA $ 0.78 ≥9M $ - NA $ 0.80

$ - NA $ 0.94 ≥9M $ - NA $ 0.98 ≥9M $ - NA $ 1.00

$ - NA $ 0.78 ≥9M $ - NA $ 0.81 ≥9M $ - NA $ 0.83

$ - NA $ 1.23 ≥9M $ - NA $ 1.27 ≥9M $ - NA $ 1.29

$ - NA $ 0.78 ≥9M $ - NA $ 0.81 ≥9M $ - NA $ 0.83

$ - NA $ 1.84 ≥9M $ - NA $ 1.88 ≥9M $ - NA $ 1.90

$ - NA $ 3.47 ≥9M $ - NA $ 3.51 ≥9M $ - NA $ 3.53

$ - NA $ 1.18 ≥9M $ - NA $ 1.22 ≥9M $ - NA $ 1.24

$ - NA $ 1.18 ≥9M $ - NA $ 1.22 ≥9M $ - NA $ 1.24

$ - NA $ 2.79 ≥9M $ - NA $ 2.83 ≥9M $ - NA $ 2.85

$ - NA $ 0.89 ≥9M $ - NA $ 0.93 ≥9M $ - NA $ 0.95
$ - NA $ 5.48 ≥9M $ - NA $ - ≥9M $ - NA $ -

$ - NA $ 7.72 ≥9M $ - NA $ - ≥9M $ - NA $ -

$ - NA $ 1.08 ≥9M $ - NA $ 1.12 ≥9M $ - NA $ 1.14

$ - NA $ 0.70 ≥9M $ - NA $ 0.73 ≥9M $ - NA $ 0.75

$ - NA $ 0.78 ≥9M $ - NA $ 0.82 ≥9M $ - NA $ 0.84

$ - NA $ 1.00 ≥9M $ - NA $ 1.04 ≥9M $ - NA $ 1.06

$ - NA $ 1.00 ≥9M $ - NA $ 1.04 ≥9M $ - NA $ 1.06

$ - NA $ 1.00 ≥9M $ - NA $ 1.04 ≥9M $ - NA $ 1.06

$ $ - NA $ $ 1.00 ≥9M $ $ - NA $ $ - ≥9M $ $ - NA $ $ -

$ - NA $ 0.67 ≥9M $ - NA $ 0.71 ≥9M $ - NA $ 0.73

$ - NA $ 0.70 ≥9M $ - NA $ 0.73 ≥9M $ - NA $ 0.75

$ - NA $ 2.60 ≥9M $ - NA $ - ≥9M $ - NA $ -

$ - NA $ 0.73 ≥9M $ - NA $ 0.76 ≥9M $ - NA $ 0.78
$ - NA $ 1.65 ≥9M $ - NA $ 2.25 ≥9M $ - NA $ 2.85

$ - NA $ 1.64 ≥9M $ - NA $ 1.85 ≥9M $ - NA $ 2.02

$ - NA $ 1.39 ≥9M $ - NA $ 1.99 ≥9M $ - NA $ 2.59

$ - NA $ 1.65 ≥9M $ - NA $ 1.65 ≥9M $ - NA $ 1.65

$ - NA $ 2.44 ≥9M $ - NA $ 3.04 ≥9M $ - NA $ 3.64

$ - NA $ 2.72 ≥9M $ - NA $ 2.92 ≥9M $ - NA $ 3.07

$ - NA $ 2.82 ≥9M $ - NA $ 3.02 ≥9M $ - NA $ 3.17

$ - NA $ 4.23 ≥9M $ - NA $ 4.53 ≥9M $ - NA $ 4.76

$ - NA $ 1.55 ≥9M $ - NA $ 2.15 ≥9M $ - NA $ 2.75

$ - NA $ 1.65 ≥9M $ - NA $ 2.25 ≥9M $ - NA $ 2.85

$ - NA $ 7.56 ≥9M $ - NA $ 7.74 ≥9M $ - NA $ 7.88

$ - NA $ 7.56 ≥9M $ - NA $ 7.74 ≥9M $ - NA $ 7.88

$ - NA $ 3.00 ≥9M $ - NA $ 3.00 ≥9M $ - NA $ 3.00

$ - NA $ 3.00 ≥9M $ - NA $ 3.00 ≥9M $ - NA $ 3.00
$ - NA $ 1.41 ≥9M $ - NA $ 2.01 ≥9M $ - NA $ 2.61

$ - NA $ 4.56 ≥9M $ - NA $ 4.75 ≥9M $ - NA $ 4.90

$ - NA $ 2.17 ≥9M $ - NA $ 2.39 ≥9M $ - NA $ 2.57

$ - $ 0.35 > 9M $ - $ 0.39 > 9M $ - $ 0.41

$ - $ 0.42 > 9M $ - $ 0.47 > 9M $ - $ 0.49

$ - $ 3.50 > 9M $ - $ - > 9M $ - $ -

$ - $ 0.75 > 9M $ - $ 0.79 > 9M $ - $ 0.81

$ - $ 0.60 > 9M $ - $ - > 9M $ - $ -

$ - $ 0.41 > 9M $ - $ 0.45 > 9M $ - $ 0.47

$ - $ 0.35 > 9M $ - $ - > 9M $ - $ -

$ - NA $ 2.38 > 4M $ - NA $ 2.38 > 4M $ - NA $ 2.38

$ - NA $ 3.41 > 4M $ - NA $ 3.41 > 4M $ - NA $ 3.41
$ - NA $ 0.84 > 4M $ - NA $ 0.84 > 4M $ - NA $ 0.84

$ - NA $ 1.41 > 4M $ - NA $ 1.41 > 4M $ - NA $ 1.41

$ - NA $ 1.93 > 4M $ - NA $ 1.93 > 4M $ - NA $ 1.93

$ - NA $ 1.44 > 4M $ - NA $ 1.44 > 4M $ - NA $ 1.44

$ - NA $ 1.52 > 4M $ - NA $ 1.52 > 4M $ - NA $ 1.52

$ - NA $ 1.45 > 4M $ - NA $ 1.45 > 4M $ - NA $ 1.45

$ - NA $ 1.50 > 4M $ - NA $ 1.50 > 4M $ - NA $ 1.50

$ - NA $ 2.83 > 4M $ - NA $ 2.83 > 4M $ - NA $ 2.83

$ - NA $ 1.93 > 4M $ - NA $ 1.93 > 4M $ - NA $ 1.93

$ - NA $ 3.21 > 4M $ - NA $ 3.21 > 4M $ - NA $ 3.21

$ - NA $ 2.82 > 4M $ - NA $ 2.82 > 4M $ - NA $ 2.82

$ - NA $ 2.28 > 4M $ - NA $ 2.28 > 4M $ - NA $ 2.28

$ - NA $ 1.15 > 4M $ - NA $ 1.15 > 4M $ - NA $ 1.15

$ - NA $ 1.24 > 4M $ - NA $ 1.24 > 4M $ - NA $ 1.24

$ - NA $ 1.20 > 4M $ - NA $ 1.19 > 4M $ - NA $ 1.18

$ - NA $ 1.10 > 4M $ - NA $ 1.10 > 4M $ - NA $ 1.10

$ - NA $ 1.18 > 4M $ - NA $ 1.18 > 4M $ - NA $ 1.18

$ - NA $ 1.14 > 4M $ - NA $ 1.14 > 4M $ - NA $ 1.15

$ - NA $ 1.20 > 4M $ - NA $ 1.19 > 4M $ - NA $ 1.18

$ - NA $ 1.14 > 4M $ - NA $ 1.13 > 4M $ - NA $ 1.12

$ - TBD $ 1.00 TBD $ - TBD $ - 1.00 $ - TBD $ -
$ - TBD $ 1.00 TBD $ - TBD $ - 1.00 $ - TBD $ -

$ - TBD $ 2.00 TBD $ - TBD $ - 2.00 $ - TBD $ -

$ - NA $ 4.92 ≥9M $ - NA $ 5.55 ≥9M $ - NA $ 6.06

$ - NA $ 8.16 ≥9M $ - NA $ 8.76 ≥9M $ - NA $ 9.21

$ - NA $ 4.50 ≥9M $ - NA $ - ≥9M $ - NA $ -

 $ - NA $ 3.50 ≥9M $ - NA $ 3.50 ≥9M $ - NA $ 3.50 

$ - NA $ 63.90 ≥ 4M $ - NA $ 82.56 ≥ 4M $ - NA $ 97.71

$ - NA $ 4.59 ≥ 4M $ - NA $ 4.59 ≥ 4M $ - NA $ 4.59
$ - NA $ 1.00 TBD $ - NA $ - TBD $ - NA $ -

$ - NA $ 0.70 ≥ 9M $ - NA $ 0.73 ≥ 9M $ - NA $ 0.75

$ - NA $ 13.68 ≥9M $ - NA $ 14.25 ≥9M $ - NA $ 14.70

$ 2.42 ≤4M $ 2.48 ≥ 4M $ - NA $ 2.88 ≥ 4M $ - NA $ 3.35

$ $ - NA $ $ 4.71 ≥ 4M $ $ - NA $ $ 4.77 ≥ 4M $ $ - NA $ $ 4.82

$ - NA $ 34.37 ≥ 4M $ - NA $ 39.36 ≥ 4M $ - NA $ 42.97
$ - NA $ 43.91 ≥ 4M $ - NA $ 50.45 ≥ 4M $ - NA $ 55.36

$ - NA $ 21.30 ≥ 4M $ - NA $ 27.52 ≥ 4M $ - NA $ 32.57

$ - $ 2.56 > 4M $ - $ 2.91 > 4M $ - $ 3.26

$ - $ 4.40 $ - $ - $ - $ -

$ - $ 2.56 > 4M $ - $ 2.91 > 4M $ - $ 3.26

$ - $ 5.31 $ - $ - $ - $ -

$ - $ 2.44 > 4M $ - $ 2.81 > 4M $ - $ 3.16

$ - $ 9.68 $ - $ - $ - $ -

$ - $ 2.11 > 4M $ - $ 2.46 > 4M $ - $ 2.81

$ - $ 2.89 $ - $ - $ - $ -

$ - $ 3.71 > 4M $ - $ 3.97 > 4M $ - $ 4.21

$ - $ 6.90 > 4M $ - $ 7.16 > 4M $ - $ 7.40

$ - $ 1.70 > 4M $ - $ 1.97 > 4M $ - $ 2.24

$ - $ 5.54 $ - $ - $ - $ -

$ - $ 2.45 > 4M $ - $ 2.89 > 4M $ - $ 3.32
$ - NA $ 12.22 ≥ 4M $ - NA $ 12.40 ≥ 4M $ - NA $ 12.53

$ - NA $ 6.00 ≥ 4M $ - NA $ 6.00 ≥ 4M $ - NA $ 6.00

$ - NA $ 5.00 ≥ 4M $ - NA $ 5.00 ≥ 4M $ - NA $ 5.00

$ - NA $ 6.00 ≥ 4M $ - NA $ 6.00 ≥ 4M $ - NA $ 6.00

$ - NA $ 20.26 $ - NA $ - $ - NA $ -

$ - NA $ 21.00 TBD $ - NA $ - TBD $ - NA $ -

$ - NA $ 1.65 ≥ 2M $ - NA $ 1.80 ≥ 2M $ - NA $ 1.94

$ - NA $ 1.59 ≥ 2M $ - NA $ 1.74 ≥ 2M $ - NA $ 1.88

$ - NA $ 1.76 ≥ 2M $ - NA $ 1.91 ≥ 2M $ - NA $ 2.05

$ - NA $ 1.74 ≥ 2M $ - NA $ 1.92 ≥ 2M $ - NA $ 2.09

$ - NA $ 1.54 ≥ 2M $ - NA $ 1.71 ≥ 2M $ - NA $ 1.89

$ - NA $ 1.54 ≥ 2M $ - NA $ 1.71 ≥ 2M $ - NA $ 1.89

$ - NA $ 1.54 ≥ 2M $ - NA $ 1.71 ≥ 2M $ - NA $ 1.89

$ - NA $ 3.03 ≥ 2M $ - NA $ 3.20 ≥ 2M $ - NA $ 3.38

$ - NA $ 3.41 ≥ 2M $ - NA $ 3.59 ≥ 2M $ - NA $ 3.76

$ - NA $ 4.00 ≥ 2M $ - NA $ - ≥ 2M $ - NA $ -

$ - NA $ 0.72 ≥ 2M $ - NA $ - $ - NA $ -

$ - NA $ 1.46 ≥ 2M $ - NA $ 1.43 ≥ 2M $ - NA $ 1.42

$ - NA $ 0.72 ≥ 2M $ - NA $ - $ - NA $ -

$ - NA $ 0.87 ≥ 2M $ - NA $ - $ - NA $ -

$ - NA $ 3.86 ≥ 2M $ - NA $ 4.45 ≥ 2M $ - NA $ 5.02

$ - NA $ 6.02 ≥ 2M $ - NA $ 6.89 ≥ 2M $ - NA $ 7.72

$ - NA $ 1.27 ≥ 2M $ - NA $ - ≥ 2M $ - NA $ -
$ - NA $ 6.70 ≥ 2M $ - NA $ 7.18 ≥ 2M $ - NA $ 7.65

$ - NA $ 2.14 > 2M $ - NA $ 2.28 > 2M $ - NA $ 2.42

$ - NA $ - $ - NA $ - $ - NA $ -

$ - NA $ 1.32 > 2M $ - NA $ 1.39 > 2M $ - NA $ 1.46

$ - NA $ 0.65 > 2M $ - NA $ 0.78 > 2M $ - NA $ 0.90

$ - NA $ 0.82 > 2M $ - NA $ 0.82 > 2M $ - NA $ 0.82

$ - NA $ 1.17 > 2M $ - NA $ 1.17 > 2M $ - NA $ 1.17

$ - NA $ 1.37 > 2M $ - NA $ 1.40 > 2M $ - NA $ 1.42

$ - $ 1.83 > 2M $ - $ 1.93 > 2M $ - $ 2.04

$ - $ 1.27 > 2M $ - $ 1.28 > 2M $ - $ 1.29

$ 12.50 < 200000 $ - $ 13.46 < 200000 $ - $ 14.42 < 200000 $ -

$ 35.18 < 200000 $ - $ 38.81 < 200000 $ - $ 42.40 < 200000 $ -

$ 24.36 < 200000 $ - $ 28.51 < 200000 $ - $ 32.65 < 200000 $ -

$ - $ 1.77 > 2M $ - $ 1.77 > 2M $ - $ 1.77

$ 4.50 < 100000 $ - $ - $ - $ - $ -

$ - NA $ 1.85 > 2M $ - NA $ 1.95 > 2M $ - NA $ 2.04

$ - NA $ 2.24 > 2M $ - NA $ 2.36 > 2M $ - NA $ 2.48

$ - NA $ 2.05 > 2M $ - NA $ 2.15 > 2M $ - NA $ 2.26

$ - $ 0.99 > 2M $ - $ 0.99 > 2M $ - $ 0.99

$ - $ 1.04 > 2M $ - $ - $ - $ -
$ - $ 1.40 $ - $ - $ - $ -

$ - $ 0.60 $ - $ - $ - $ -

$ - $ 1.65 > 2M $ - $ 1.65 > 2M $ - $ 1.65

$ - $ 2.10 > 2M $ - $ 2.10 > 2M $ - $ 2.10

$ - $ 20.00 > 2M $ - $ 20.00 > 2M $ - $ 20.00

$ - $ 0.56 $ - $ 0.56 $ - $ 0.56

$ - $ 20.00 > 2M $ - $ - > 2M $ - $ -

$ - $ 15.00 > 2M $ - $ - > 2M $ - $ -

$ - $ 15.00 > 2M $ - $ - > 2M $ - $ -

$ - $ 20.00 > 2M $ - $ - > 2M $ - $ -

$ - $ 250.00 > 2M $ - $ - > 2M $ - $ -

$ - $ 178.57 > 2M $ - $ - > 2M $ - $ -

$ - $ 250.00 > 2M $ - $ - > 2M $ - $ -

$ - $ 0.16 TBD $ - $ - TBD $ - $ -

$ - $ 1.50 TBD $ - $ - TBD $ - $ -
(approx 

based off 

Zmk#3)

(approx 

based off 

Zmk#3)

(approx 

based off 

Zmk#3)
e compared to the material under 

 to obtain the cost of the base 

ultiplied by the delta percentage 

as added to the cost to obtain the 

alert their customers of pending 
≥9M AMM Reference, MEPS, USGS

≥9M Online Metals, Metals Depot, Speedy Metals, All Metals, 

Industrial Metal Sales w/ AMM spot check

≥9M

≥9M

Premium Steel

≥9M Metals Express, Industrial Metal, Online Metals, Metals 

Depot

≥9M Online Metals, Speedy Metals, All Metals

≥9M Online Metals, Speedy Metals, All Metals

≥9M Purchasing Magazine

≥9M Estimated same pricing as 1215 bar.

Information Reference Source

High Annual 

Consumption 

Rate 

≥9M Assigned same rate as A-Steel-4140, Bar 0.875-2.75"

≥9M Composition analysis plus surcharge

≥9M Smith Advanced Metals (England)

≥9M Online Metals, metals express, Aircraft Spruce & Specialty 

Co. & Specialty Co.

≥9M Online Metals, metals express, Aircraft Spruce & Specialty 

Co. & Specialty Co.

≥9M Composition analysis plus surcharge

≥9M Metals Depot, Aircraft Spruce & Specialty Co., All Metals, 

Metal Connection

≥9M Online Metals, metals express, Speedy Metals, Hi-Tech 

Metals Quote

≥9M Speedy Metals

≥9M Kmac

≥9M Surrogate pricing based on 4130 0.040"-0.125"

≥9M Online Metals, Aircraft Spruce & Specialty Co. & Specialty 

Co.

≥9M Kmac

≥9M Composition analysis plus surcharge
≥9M Metal Suppliers Online, Rick Aldrich 

≥9M California Metals

≥9M Online Metals, Metals Express, Hi Tech Metals quote

≥9M Composition analysis plus surcharge

≥9M Kmac, Speedy Metals Express

≥9M Surrogate pricing based on "A-Steel-5140, Bar"

≥9M Kmac, Raker, Continental Steel Quote

≥9M Kmac, Raker, Continental Steel Quote

≥9M Surrogate pricing based on "A-Steel-52100 Bar"

≥9M Kmac

≥9M Composition analysis plus surcharge

≥9M Macsteel

≥9M Composition analysis plus surcharge
≥9M MEPS, stainlesssteel.com, purchasing.com

≥9M MEPS, stainlesssteel.com, purchasing.com

≥9M MEPS, stainlesssteel.com, purchasing.com

≥9M Estimate, same pricing as 304Bar

≥9M MEPS, stainlesssteel.com, purchasing.com

≥9M MEPS, stainlesssteel.com, purchasing.com

≥9M MEPS, stainlesssteel.com, purchasing.com

≥9M Place Holder 1.5 x $ "S-Steel-316, Cast"

≥9M MEPS, stainlesssteel.com, purchasing.com

≥9M MEPS, stainlesssteel.com, purchasing.com

≥9M Point Price from Bundy with trend analysis.

≥9M Point Price from Power Plant Services with trend analysis.

≥9M Need Pricing Confirmation

≥9M Need Pricing Confirmation
≥9M MEPS, Stainlesssteel.com, Purchasing.com

≥9M Point Price from AK Steel with trend analysis.

≥9M Point price from AMM with trend analysis.

> 9M AISI, MEPS

> 9M Estimate base on ASTM A536-80-55-06

> 9M Estimate from Tech. Expert in Turbocharger 

Assemblies ,Steve Arnold

> 9M Somerset Foundries

> 9M Estimate from Tech. Expert in Turbocharger 

Assemblies ,Steve Arnold

> 9M AISI, MEPS

> 9M Estimate same pricing as ASTM A536-80-55-06

> 4M Aircraft Spruce & Specialty Co. & Specialty Co., Online 

Metals, Industrial Metal

> 4M Online Metals, Kmac, Airparts
> 4M Aluminum.com, AMM reference.

> 4M Aluminum.com, AMM reference.

> 4M Lynch Estimate

> 4M Kmac

> 4M Online Metals, Metal Depot, Airparts, Enco, All Metals

> 4M Online Metals

> 4M Metals Express, Aircraft Spruce & Specialty Co., All 

Metals, Metal Connection

> 4M Aircraft Spruce & Specialty Co., Metals Depot, Online 

Metals, Airpart

> 4M Aircraft Spruce & Specialty Co., Metals Depot, Online 

Metals, Airpart

> 4M Aluminum.com, AMM reference

> 4M Industrial Metal, Online Metals

> 4M Lynch Estimate

> 4M CRU group, AMM reference

> 4M CRU group, AMM reference

> 4M CRU group, AMM reference

> 4M CRU group, AMM reference

> 4M CRU group, AMM reference

> 4M CRU group, AMM reference

> 4M CRU group, AMM reference

> 4M CRU group, AMM reference

 1.00 Need source from Sue if available.
 1.00 Base on SAE1541, Call Fred Deshaw

 2.00 Need Price confirmation

≥9M 3x Cost of 304 Coil - reference above

≥9M 3x Cost of 316 Coil - reference above

≥9M Need Pricing Confirmation

≥9M Need Pricing Confirmation

≥ 4M Consultations from PM makers

≥ 4M Need Pricing Confirmation
TBD Need source from Sue if available.

≥ 9M Composition analysis plus surcharge

≥9M 3x S-Steel-440C, Bar

≥ 4M USGS, AMM Reference, Purchasing

Centracore, Mark Luchese (09/1709) Low Volume Rate

≥ 4M USGS

≥ 4M Longbow
≥ 4M Longbow

≥ 4M Longbow

> 4M InfoMine for copper plus composition analysis

Spectrum Machine

> 4M Estimate based on C93200

Wisco Alloys

> 4M InfoMine for copper plus composition analysis

Spectrum Machine

> 4M InfoMine for copper plus composition analysis

Colonial Metals Co., Tom Long

> 4M Atlas Bronze Quote (quote price plus copper trend line)

> 4M Atlas Bronze Quote (quote price plus copper trend line)

> 4M InfoMine for copper plus composition analysis

Spectrum Machine

> 4M InfoMine
≥ 4M Point price from Special Metals WV with trend analysis.

≥ 4M Pricing estimate from Turbocharger Tech. Expert, 

Steve Arnold

≥ 4M Need Material and Pricing Confirmation

≥ 4M Pricing estimate from Turbocharger Tech. Expert, 

Steve Arnold

No Reference Source Identified by Sue Okray

TBD Need Reference Source

≥ 2M IDES, Plastic News

≥ 2M IDES, Plastic News, Plastic Technology

≥ 2M IDES, Plastic News, Plastic Technology

≥ 2M IDES, Plastic News

≥ 2M IDES, Plastic News

≥ 2M IDES, Plastic News

≥ 2M Estimate based on PA

≥ 2M IDES, Plastic News, Plastic Technology

≥ 2M IDES, Plastic News, Plastic Technology

≥ 2M Need Pricing Confirmation

Need Confirmation Source

≥ 2M IDES, Plastic News

Plastic News

Need Confirmation Source

≥ 2M IDES, Plastic News

≥ 2M IDES, Plastic News

≥ 2M Need Confirmation Source
≥ 2M IDES, Plastic News

> 2M CMAI, Rubber Statistical Bulletin

> 2M CMAI, Rubber Statistical Bulletin

> 2M CMAI

> 2M The Innovation Group

> 2M The Innovation Group, Plastics News (for delta)

> 2M The Innovation Group

> 2M The Innovation Group

> 2M The Innovation Group

Plastics News

PT online, Plastic News - Trend line from surrogate 

materials

PT online, Plastic News - Trend line from surrogate 

materials

> 2M Rubber and Plastics News

Need Supporting Reference

> 2M 1.40 x $SBR

> 2M 1.70 x $SBR

> 2M 1.55 x $SBR

> 2M Plastics News

Plastics News, Hutsmann
Need Pricing Confirmation Source

Need Pricing Confirmation Source

> 2M Sue received feedback from Alcoa (3/27/09)

> 2M Sue received feedback from Alcoa (3/27/09)

> 2M Need Pricing Confirmation Source

http://metalprices.com/

> 2M Need Pricing Confirmation Source

> 2M Need Pricing Confirmation Source

> 2M Need Pricing Confirmation Source

> 2M Need Pricing Confirmation Source

> 2M Need Pricing Confirmation Source

> 2M Need Pricing Confirmation Source

> 2M Need Pricing Confirmation Source

TBD Need Pricing Confirmation Source

TBD Need Pricing Confirmation Source
Mat'l composition, mechanical and physical properties can be found @ 

http://www.eazall.com/diecastalloys.aspx