Appendix G.1 - Subsystem 03

Crank Drive Subsystem

 Case Study #0101

MAQS Worksheets

File:Crank Drives 03, 032509.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-03, 1 of 7
Crankshaft 0301 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Loca

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Loca

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Met

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specifica

Component Description: Shaft - Crank Part Number: 0301-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark-up Rate Total Mark-up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 2 * Qty per Ass'y

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

Shaft - Crank (Mini Cooper) 0301-N0101-01 1

Considered for Weight Delta 

Only, Assume Fabrication and Machining times a wash between Mini and Chrysler Crankshaft

OEM MA-Steel-MnVS, Bar Not Applicable Not Applicable 116 0 25.28 $0.73 $0.00 $0.00 $18.45 $0.00 $0.00 $18.45 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $18.45 $1

Shaft - Crank ( Chrysler Gema) 0301-B0101-01 1 "See Note Above" OEM MA-Steel-MnVS, Bar Not Applicable Not Applicable 116 0 -39.81 $0.73 $0.00 $0.00 -$29.06 $0.00 $0.00 -$29.06 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$29.06 -$

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, PIA

Purch

Net, 

0 $0.00 $0.00 $0.00 $

0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Mark- up -$

T1 or OEM Total Manufacturing Cost: -$10.61 $0.00 $0.00 -$10.61 $0.00 $0.00 $0.00 $0.00 $0.00 -$

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 8.00% 0.00% 15.70%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- -$0.07 -$0.74 -$0.85 $0.00 -$1.67

Base Cost Impact to Vehicle: -$10.61 $0.00 $0.00 -$10.61 -$0.07 -$0.74 -$0.85 $0.00 -$1.67 -$

Packaging Cost: $

Net Cost Impact to Vehicle: -$

Packaging Calculations 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 

In-transit 

Inventory 

Requirements 

(Weeks)

Supplier, 

Customer and Intransit Inventory 

Requirements 

(Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 6 57447

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

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS TOTAL COS

10

9,574

47

450,000

1

450,000

PACKAGIAssume N

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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

1

File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-03, 2 of 7
Con.Rod0303 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Loca

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Loca

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Me

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specifica

Component Description: Rod Subassembly - Connecting Part Number: 0303-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark-up Rate Total Mark-up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 2  Qty per Assy

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

1A Rod Subassembly - Connecting 0303-N0101-01-01 1

Weight Cost Differential Only, Fabrication and Machining are equivalent between Mini & Chrysler Con. Rods.Mini-Cooper RodL/R = 138.5/(85.9/2) = 3.22

S MA-Steel-C70S6, Bar Not Applicable Not Applicable 450 0 0.964 $0.70 $0.00 $0.00 $0.67 $0.00 $0.00 $0.67 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.67 

1B Rod Subassembly - Connecting 0303-N0101-01 1 Install Bushing & Size S Not Applicable General Assembly Mech. Assembly, MC 450 0 0.000 $0.00 $35.51 $125.19 $0.00 $0.00 $0.28 $0.28 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.28 2A Rod Subassembly - Connecting 0303-B0101-01&02 1 Chrysler GEMA Rod Weight MA-Steel-C70S6, Bar Not Applicable Not Applicable 450 0 -0.979 $0.70 $0.00 $0.00 -$0.69 $0.00 $0.00 -$0.69 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$0.69 -2B Rod Subassembly - Connecting 0303-B0101-01&02-M 1

Additional Material Required to Equalize L/R RatioGEMA Prod. L/R = 2.96, R = 97/2 = 48.5 & L =143.75mmAssuming Mini L/R (3.22).Hold stroke constant L=3.22*48.5= 156.17mmTherefore rod length would increase by 12.42mm

MA-Steel-C70S6, Bar Not Applicable Not Applicable 450 0 -0.032 $0.70 $0.00 $0.00 -$0.02 $0.00 $0.00 -$0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$0.02 -

Purchase Part - Commodity ( Value taken from Purchase Part Database) Supplier Account Cost Purchase Price/ Unit Purchase Price Net, PIA Purc

Net, 

Bushing - Connecting Rod 0303-N0101-02 1 Aluminum Bronze S $0.00 $0.33 $0.00 

0 (Blank 40x30x0.5 mmm) $0.00 $0.00 $0.00 0 Mean ρ = 0.270 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 

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

T1 or OEM Total Manufacturing Cost: $0.30 $0.00 $0.28 $0.58 $0.00 $0.00 $0.00 $0.00 $0.00 

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

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.04 $0.03 $0.01 $0.09

Base Cost Impact to Vehicle: $0.30 $0.00 $0.28 $0.58 $0.00 $0.04 $0.03 $0.01 $0.09 

Packaging Cost: 

Net Cost Impact to Vehicle: 

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS TOTAL CO

10

38,298

47

450,000

4

1,800,000

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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

1

File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-03, 3 of 7
Con.Rod0303 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Loca

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Loca

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Me

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specifica

Component Description: Rod Subassembly - Connecting Part Number: 0303-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark-up Rate Total Mark-up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 2  Qty per Assy

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS TOTAL CO

10

38,298

47

450,000

4

1,800,000

Packaging Calculations 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 

In-transit 

Inventory 

Requirements 

(Weeks)

Supplier, 

Customer and 

In-transit 

Inventory 

Requirements 

(Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 18,000,000 60 5.00% $0 229787 1 6 229787

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 $1.00 0 $3.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

PACKAGNo Chang

File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-03, 4 of 7
Piston0304 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Piston - Engine, Machined Part Number: 0304-N0101-01 Weekly Component Volume: P

Component Quote Level: Estimated Product Life:

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) P

R

(D

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

1A Piston - Engine, Cast (Mini Cooper) 0304-N0101-01-01 1

Consider weight, material and scrap (+5%) differences in cast hypereutectic material.

T2/T3 Internal Supplier Aluminum-B390, Cast Mold/Cast/Sinter Operator Diecast, LMC 517 3 3 1 0.651 $1.20 $43.52 $100.05 $300.15 $0.78 $0.25 $0.58 $1.61 5.00% 0.00% 0.

1B Piston - Engine, Machined (Mini Cooper) 0304-N0101-01-01 1 T6 Heat Treat T2/T3 Internal Supplier Not Applicable Heat Treat Operator Heat Treat, SMS, MHC 442 2 4 1 0.000 $0.00 $46.52 $100.00 $400.00 $0.00 $0.21 $0.90 $1.12 0.00% 0.00% 0.

1C Piston - Engine, Machined (Mini Cooper) 0304-N0101-01 1 Machining (5% Premium on Time Accounted for in rate) T2/T3 Internal Supplier Not Applicable CNC Operator Rot./Lin. Trans. Machining Line, TP, PREM. 480 1 2 1.05 0.000 $0.00 $35.70 $260.00 $546.00 $0.00 $0.07 $1.14 $1.21 0.00% 0.00% 0.

2A Piston - Engine, Machined (Chrysler GEMA)) 0304-B0101-01-01 1

Consider weight and material differences only as cost factor in primary fabrication process.

T2/T3 Internal Supplier Aluminum-384, Cast Mold/Cast/Sinter Operator Diecast, LMC -514 3 3 1 -0.764 $1.14 $43.52 $100.05 $300.15 -$0.87 -$0.25 -$0.58 -$1.71 0.00% 0.00% 0.

2B Piston - Engine, Machined (Chrysler GEMA)) 0304-B0101-01-01 1 T5 Heat Treat T2/T3 Internal Supplier Not Applicable Heat Treat Operator Heat Treat, SMS, LMC -420 1 2 1 0.000 $0.00 $46.52 $50.00 $100.00 $0.00 -$0.11 -$0.24 -$0.35 0.00% 0.00% 0.

2C Piston - Engine, Machined (Chrysler GEMA)) 0304-B0101-01-01 1 Machining T2/T3 Internal Supplier Not Applicable CNC Operator

Rot./Lin. Trans. Machining Line, TP -480 1 2 1 0.000 $0.00 $35.70 $250.00 $500.00 $0.00 -$0.07 -$1.04 -$1.12 0.00% 0.00% 0.

0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #

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

0 0 0 0 0 0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap SG&A P

T1 or OEM Total Manufacturing Cost: -$0.09 $0.10 $0.76 $0.77 $0.08 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.06 $

Base Cost Impact to Vehicle: -$0.09 $0.10 $0.76 $0.77 $0.08 $0.06 $

47

450,000

4

1,800,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

38,298

10

M

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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.

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

Note, both the Mini and Chrysler GEMA pistons have anodized top ring groove and a dry-film skirt coating.

File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-03, 5 of 7
Piston0304 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Piston - Engine, Machined Part Number: 0304-N0101-01 Weekly Component Volume: P

Component Quote Level: Estimated Product Life:

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) P

R

(D

47

450,000

4

1,800,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

38,298

10

M

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

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

Rack

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 18,000,000 60 5.00% $0 250 

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

Ot

Pac

Pri

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

Packaging Cost Total: $0.000

 PACKAGING CALCULATIONS: Packaging Type: NO CHANGE TO PACKAGINGPart Size:Parts/Layer:Number of Layers:

File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-03, 6 of 7
Engine Assembly 0300 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Engine Assembly of Crank Drive Subsystem Components Part Number: 0300-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) 

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

0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 

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

1A Shaft - Crank 0301-N0101-01 1 (OEM Mark-up included in Crankshaft Worksheet) 

2A Rod Subassembly - Connecting 0303-N0101-01 4 SAC 3A Piston - Engine, Machined 0304-N0101-01 4 SAC 4A Ring/Clip - Piston Pin Retainer 0304-N0101-02 8 S 5A Pin- Piston 0304-N0101-03 4

GEMA 15Cr3(SAE5015) Case HardenedMini 31CrMoV9 Nitrided

S 

6A Compression Ring - Piston, Top 0304-N0101-04 4 S 7A Compression Ring - Piston, 2nd 0304-N0101-05 4 S 8A Spacer/Expander/Coil Spring - Oil Ring, Piston 0304-N0101-07 4 S 9A Rail(s) - Oil Ring, Piston 0304-N0101-08 4 S 

10A Bearing - Connecting Rod to Crank Shaft 0390-N0101-01 8 AlSn20Mn Base, AlSn10Ni Turbo DI S 

0 0 0 0 

Material Labor Burden TMC Scrap SG&A 

T1 or OEM Total Manufacturing Cost: $12.27 $0.00 $0.00 $12.27 $0.00 $0.00 

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

(SAC) &T1 or OEM Mark-Up Values: (6.58) ----- ----- ----- $0.00 $0.00 

Base Cost Impact to Vehicle: $5.69 $0.00 $0.00 $5.69 $0.00 $0.00 

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

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 250 

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 #

Pads 

Pallet/Ra

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: Packaging Type: No Changes Required to PackagingPart Size:Parts/Layer:Number of Layers:

"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.

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

No impact to engine assembly. Assume wrist pin retaining clip labor/burden add would be offset by labor/burden press fit pin design.

File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-03, 7 of 7
Appendix G.1 - Subsystem 04

Counter Balance Subsystem

 Case Study #0101

MAQS Worksheets

File:Counter Balance, 031908.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-04, 1 of 4
Balance Shaft Subassembly 0401 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hp Annual Component Volume: 

Component Description: Balance Shaft Assembly ( Part of Oil Pump Assembly) Part Number: 0401-B0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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 

Mutiplier

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) 

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

1A Upper and Lower Housing assembly Machining 0401-B0101-11-01 1 Assemble upper and lower housings, machine bearings. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 240 2 1 8 0.000 $0.00 $35.51 $15.00 $120.00 $0.00 $0.30 $0.50 $0.80 0.00% 0.00% 2A Balance Shaft Long and Short 0401-B0101-06/07 2 Press Gears onto balance shafts. (1 of each shaft type) T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 240 1 2 1 0.000 $0.00 $35.51 $15.00 $30.00 $0.00 $0.15 $0.13 $0.27 0.00% 0.00% 3A Final Assembly of Balance Shaft Assembly 0401-B0101-01 1 Assemble Shafts into Houisng and rundown fasteners. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 240 4 1 5 0.000 $0.00 $35.51 $15.00 $75.00 $0.00 $0.59 $0.31 $0.90 0.00% 0.00% 

Purchase Part - High Impact Item (Full Cost Mapping)

1A Bottom Housing Casting 0401-B0101-03-1-1 1 Casting T2/T3 Diecast, MSMC Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC 112 1 1 1 2.351 $1.10 $43.52 $100.05 $100.05 $2.59 $0.39 $0.89 $3.87 5.00% 6.50% 1B Bottom Housing Casting 0401-B0101-03-1 1 Machine Casting T2/T3 Diecast, MSMC Not Applicable CNC Operator CNC Machining, LMC 115 1 1.5 1 0.000 $0.00 $35.70 $25.00 $37.50 $0.00 $0.31 $0.33 $0.64 5.00% 6.50% 2A Top Housing Balance Shaft Casting 0401-B0101-08-1-1 1 Casting T2/T3 Diecast, MSMC Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC 111 1 1 1 2.609 $1.10 $43.52 $100.05 $100.05 $2.87 $0.39 $0.90 $4.17 5.00% 6.50% 2B Top Housing Balance Shaft 0401-B0101-08-1 1 Machine Casting T2/T3 Diecast, MSMC Not Applicable CNC Operator CNC Machining, LMC 114 1 2 1 0.000 $0.00 $35.70 $25.00 $50.00 $0.00 $0.31 $0.44 $0.75 5.00% 6.50% 3A Balance Shaft Short Casting 0401-B0101-06-1-1-1 1 Casting T2/T3 Diecast, MSMC Nodular Iron, Cast Mold/Cast/Sinter Operator Perm. Cast, LMC 242 3 1 1 1.721 $0.35 $43.52 $100.06 $100.06 $0.60 $0.54 $0.41 $1.56 5.00% 6.50% 3B Balance Shaft Short Casting 0401-B0101-06-1-1-1 1 Heat Treating T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 242 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.19 $0.41 $0.61 0.50% 6.50% 

3C Balance Shaft Short Machined 0401-B0101-06-1-1 1 Machine T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, HC 113 0.5 1.5 1 0.000 $0.00 $35.70 $75.00 $112.50 $0.00 $0.16 $1.00 $1.16 0.50% 6.50% 3D Balance Shaft Short Machined 0401-B0101-06-1-1 1 Grind T2/T3 CNC Turning, MSMC Not Applicable CNC Operator Grinding, SMS, MHC 132 0.5 1.25 1 0.000 $0.00 $35.70 $65.00 $81.25 $0.00 $0.13 $0.61 $0.75 0.50% 6.50% 

3E Balance Shaft Short Machined 0401-B0101-06 1 Balance T2/T3 CNC Turning, MSMC Not Applicable CNC Operator Balancing, MLS, LMC 120 0.5 1 1 0.000 $0.00 $35.70 $25.00 $25.00 $0.00 $0.15 $0.21 $0.36 0.50% 6.50% 4A Balance Shaft Short Casting 0401-B0101-07-1-1-1 1 Casting T2/T3 Diecast, MSMC Nodular Iron, Cast Mold/Cast/Sinter Operator Perm. Cast, LMC 226 3 1 1 2.242 $0.35 $43.52 $100.06 $100.06 $0.78 $0.58 $0.44 $1.80 5.00% 6.50% 4B Balance Shaft Short Casting 0401-B0101-07-1-1-1 1 Heat Treating T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 242 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.19 $0.41 $0.61 0.50% 6.50% 

4C Balance Shaft Short Machined 0401-B0101-07-1-1 1 Machine T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, HC 114 0.5 2.25 1 0.000 $0.00 $35.70 $75.00 $168.75 $0.00 $0.16 $1.48 $1.64 0.50% 6.50% 4D Balance Shaft Short Machined 0401-B0101-07-1-1 1 Grind T2/T3 CNC Turning, MSMC Not Applicable CNC Operator Grinding, SMS, MHC 142 0.5 1.3 1 0.000 $0.00 $35.70 $65.00 $84.50 $0.00 $0.13 $0.60 $0.72 0.50% 6.50% 

4E Balance Shaft Short Machined 0401-B0101-07 1 Balance T2/T3 CNC Turning, MSMC Not Applicable CNC Operator Balancing, MLS, LMC 120 0.5 1 1 0.000 $0.00 $35.70 $25.00 $25.00 $0.00 $0.15 $0.21 $0.36 0.50% 6.50% 5A Gear Balance Shaft 0401-B0101-06-2-1 2 Machine Blank & Hob Teeth (Same process for both Gears) T2/T3 CNC Turning, MSMC LC-Steel-1215, Bar CNC Operator Balancing, MLS, LMC 235 2 4.5 1 0.000 $0.62 $35.70 $25.00 $112.50 $0.00 $0.30 $0.48 $0.78 0.50% 6.50% 5B Gear Balance Shaft 0401-B0101-06-2-1 2 Heat Treating T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC 360 1 1 1 0.000 $0.00 $46.52 $50.00 $50.00 $0.00 $0.13 $0.14 $0.27 0.50% 6.50% 

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

1A Dowel Upper to lower housing alignment 0401-B0101-04 2 S 

2A Bearing Shell Balance Shaft 0401-B0101-05 4 S 3A Bolt Balance Shaft Housing 0401-B0101-09 6 S 4A Cap Shaft Close out 0401-B0101-10 2 S 

0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap SG&A 

T1 or OEM Total Manufacturing Cost: $8.53 $5.83 $10.65 $25.01 $0.68 $1.37 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.14 $1.85 

Base Cost Impact to Vehicle: $8.53 $5.83 $10.65 $25.01 $0.82 $3.22 

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

"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.

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

File:Counter Balance, 031908.xlsEPA Contract: EP-C-07-069 WA1-3 APpendix, G.1-04, 2 of 4
Balance Shaft Subassembly 0401 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hp Annual Component Volume: 

Component Description: Balance Shaft Assembly ( Part of Oil Pump Assembly) Part Number: 0401-B0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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 

Mutiplier

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) 

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

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

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

Rack/Pallet Investment Amortization: $0.053 $105,000 0.00% 2,250,000 60 5.00% $420 250 

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 #

Pads 

Pallet/Ra

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

Packaging Cost Total: $0.053

 PACKAGING CALCULATIONS: Consider additional volume as result of Balance Shaft subassembly:Packaging Type: Option #2Part Size: 190x220 x120Parts/Layer: 5 x 5Number of Layers:7

File:Counter Balance, 031908.xlsEPA Contract: EP-C-07-069 WA1-3 APpendix, G.1-04, 3 of 4
Engine Assembly 04 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Engine Assembly of Balance Shaft Assembly Part Number: Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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 

Mutiplier

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) S

R

(

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

Mount Balance Shaft Assembly to Engine 0401-B0101-01 1 Install Balance Shaft Assembly to block, 4 Bolts. OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Engine Assembly, OEM 212 1 1 1 0.000 $0.00 $83.31 $150.21 $150.21 $0.00 $0.39 $0.71 $1.10 0.00% 0

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

1A Bolt - Balance Shaft Assembly Mount to Block PC 12.9 4 (Packaging Included in Cost) S 

2A Balance Shaft Assembly ( Part of Oil Pump Assembly) 0401-B0101-01 1 SAC 

0 0 0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $34.84 $0.39 $0.71 $35.95 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

(SAC) &T1 or OEM Mark-Up Values: (33.01) ----- ----- ----- $0.00 

Base Cost Impact to Vehicle: $1.83 $0.39 $0.71 $2.93 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 

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

O

Pa

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

Packaging Cost Total: $0.000

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

 PACKAGING CALCULATIONS: Packaging Type:Part Size:Parts/Layer:Number of Layers:

"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.

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

File:Counter Balance, 031908.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-04, 4 of 4
Appendix G.1 - Subsystem 05

Cylinder Block Subsystem

 Case Study #0101

MAQS Worksheets

File:Cylinder Block 05, 032509.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-05, 1 of 8
Cylinder Block 0501 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Location

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Location

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Method

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specification

Component Description: Cylinder Block Assembly - Machined w. Studs, Plugs, etc. Part Number: 0501-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 3 = 

Total 2 * Qty per Ass'y

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

1A Cylinder Block Subassembly - Machined w/o Studs/Plugs, etc 0501-N0101-01 (Mini Cooper) 1 Upper cylinder block machining OEM Not Applicable CNC Operator-OEM CNC Milling, LS, HC 135 0.25 0.000 $0.00 $68.07 $250.00 $0.00 $0.13 $1.86 $1.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.98 $1.981B Cylinder Block Subassembly - Machined w/o Studs/Plugs, etc 0501-B0101-01 ( Chrysler GEMA) 1 Machining operation adds for mounting balance shaft assembly. OEM Not Applicable CNC Operator-OEM CNC Milling, LS, HC -288 0.25 0.000 $0.00 $68.07 $250.00 $0.00 -$0.06 -$0.87 -$0.93 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$0.93 -$0.93

1C Cylinder Block Subassembly - Cast 0501-N0101-03 1

Main Cooper Block minus liners =29.19Chrysler GEMA Block minus liners = (33.655 + 2.08)

OEM Aluminum-A380, Cast Not Applicable Not Applicable 89 0 -6.545 $1.10 $0.00 $0.00 -$7.20 $0.00 $0.00 -$7.20 5.00% 0.00% 0.00% 0.00% 5.00% -$0.36 -$7.56 -$7.56

0 ##### 0 0.000 #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 $0.000 ##### 0 0.000 #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 $0.000 ##### 0 0.000 #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 $0.000 ##### 0 0.000 #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 $0.000 ##### 0 0.000 #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 $0.000 ##### 0 0.000 #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 $0.000 ##### 0 0.000 #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 $0.000 ##### 0 0.000 #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

Purchase Part - High Impact Item (Full Cost Mapping)

1A Cylinder Liners - Cast Iron

0501-N0101-04

4

Mini Cooper Liners = 1.9 lbs/liner, Chrysler GEMA Engine = 2.44lbs/liner

OEM Nodular Iron, Cast Not Applicable Not Applicable 

450 0 -0.540 $0.35 $0.00 $0.00 -$0.19 $0.00 $0.00 -$0.19 0.30% 6.00% 4.00% 0.00% 10.30% -$0.02 -$0.21 -$0.83

0 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10.30% #N/A #N/A $0.000 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10.30% #N/A #N/A $0.000 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10.30% #N/A #N/A $0.000 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10.30% #N/A #N/A $0.000 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10.30% #N/A #N/A $0.000 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10.30% #N/A #N/A $0.00

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

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

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Mark-up -$7.34

T1 or OEM Total Manufacturing Cost: -$7.96 $0.07 $0.99 -$6.90 -$0.36 -$0.05 -$0.03 $0.00 -$0.44 -$7.34

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 8.00% 0.00% 15.70%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- -$0.05 -$0.51 -$0.59 $0.00 -$1.15

Base Cost Impact to Vehicle: -$7.96 $0.07 $0.99 -$6.90 -$0.41 -$0.56 -$0.62 $0.00 -$1.59 -$8.49 

Packaging Cost: $0.00

Net Cost Impact to Vehicle: -$8.49

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS TOTAL COSTS

1 

450,000 

9,574

47 

450,000 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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

1

Timing Chain Cover Adds 3.98 lbs to Chrysler GEMA Head, Block, Girdle. Divided by coverage contribution:Head 130/450 = 28.9% or 1.15lbsBlock = 235/450 = 52.2% or 2.08 lbsGirdle = 85/450 = 18.9% or 0.75Mini Cooper has integrated Cover in Head/Block/Bead Plate

NA

Assume casting speed for Chrysler and Mini Cooper Block will be approximately the same. Thus no additional Labor or Burden costs were accounted for.

Assume processing speed for Chrysler and Mini Cooper liners will be approximately the same. Thus no additional Labor or Burden costs were accounted for.

NA

File:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-05, 2 of 8
Cylinder Block 0501 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Location

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Location

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Method

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specification

Component Description: Cylinder Block Assembly - Machined w. Studs, Plugs, etc. Part Number: 0501-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 3 = 

Total 2 * Qty per Ass'y

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS TOTAL COSTS

1 

450,000 

9,574

47 

450,000 

Packaging Calculations 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 

Requiremen

ts (Weeks)

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 6 57447

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 CANegligible Affect 

File:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-05, 3 of 8
Bed Plate 0503 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Bed Plate Assembly - Machined w. Studs, Plugs, etc. Part Number: 0503-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate 

M

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

A1.1 Bed Plate Subassembly - Cast

0503-N0101-02

1 Bed Plate casting OEM Aluminum-A380, Cast Not Applicable Not Applicable 107 0 -3.663 $1.10 $0.00 $0.00 -$4.03 $0.00 $0.00 -$4.03 5.00% 0.00% 0.00% 0.00% 

#DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 

0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 

Purchase Part - High Impact Item (Full Cost Mapping)

1A Bearing Cap - Bolt Through - Insert, Steel 0503-N0101-03 5 Main Bearing Caps, Cast S Nodular Iron, Cast Not Applicable Not Applicable 554 0 -0.190 $0.35 $0.00 $0.00 -$0.07 $0.00 $0.00 -$0.07 5.00% 6.00% 4.00% 0.00% 1

0 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 10 #DIV/0! 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.30% 6.00% 4.00% 0.00% 1

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

S

A

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

1 

450,000 

9,574

47 

450,000 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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.

Mini Cooper Bed Plate integrated Bearing Cap Weight = 18.01 lbsChrysler Girdle has non integrated bearing capsWeight of Girdle =17.423+ Cover Contribution 0.75 -Oil Filter Inlet 0.25 lbs = 17.923Weight of Caps = 0.94/bs/CapRatio of Cap/(Cap+Girdle) = 20.8% Therefore for Mini Cooper assumption is that 20.8% of Bedplate weight are for Bearing Caps, Thus the following calculations are made:Weight of Base Bed Plate Material = 79.2%x18.01 = 14.26 lbsWeight of Bearing Caps = 20.8%x18.01 = 3.75 lbs

Assume casting speed for Chrysler and Mini Cooper Bed Plate will be approximately same. Thus no additional Labor or Burden costs were accounted for.

NA

Assume casting speed for Chrysler and Mini Cooper Bearing Caps will be approximately the same. Thus no additional Labor or Burden costs were accounted for.

NA

File:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-05, 4 of 8
Bed Plate 0503 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Bed Plate Assembly - Machined w. Studs, Plugs, etc. Part Number: 0503-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate 

M

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

1 

450,000 

9,574

47 

450,000 

0 

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

M

T1 or OEM Total Manufacturing Cost: -$4.36 $0.00 $0.00 -$4.36 -$0.22 -$0.02 -$0.01 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 8.00% 0.00% 1

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- -$0.03 -$0.32 -$0.37 $0.00 

Base Cost Impact to Vehicle: -$4.36 $0.00 $0.00 -$4.36 -$0.25 -$0.34 -$0.38 $0.00 

Packaging Calculations 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

S

C

I

Re

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 

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

Pa

Expendable Packaging in Piece Cost: $0.00 $1.00 0 $3.00 0 $0.00 0 $0.00 0 $0.00 

Packaging Cost Total: $0.000

File:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-05, 5 of 8
Piston Cooling 0504 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Squirter - Oil, Piston Cooler & Retainer Part Number: 0504-N0101-01/02 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

1A Bolt - Piston Cooler Valve/Retainer 0504-N0101-02 1 Purchase Part Cost Est. Break OutS Purchased Parts General Assembly Mech. Assembly, LC 206 0.5 0.350 $1.00 $35.51 $100.19 $0.35 $0.09 $0.49 $0.92 0.30% 6.00% 4.00% 0.00% 102A Squirter - Oil, Piston Cooler 0504-N0101-01 1 Purchase Part Cost Est. Break OutS Purchased Parts General Assembly Mech. Assembly, LC 240 0.5 0.300 $1.00 $35.51 $100.19 $0.30 $0.07 $0.42 $0.79 0.30% 6.00% 4.00% 0.00% 10

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

Su

Ac

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

Ma

T1 or OEM Total Manufacturing Cost: $0.65 $0.16 $0.90 $1.71 $0.01 $0.10 $0.07 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 0.00% 10

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.11 $0.08 $0.00 $

Base Cost Impact to Vehicle: $0.65 $0.16 $0.90 $1.71 $0.01 $0.22 $0.14 $0.00 $

Packaging Calculations 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

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 18,000,000 60 5.00% $0 460 500 

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

O

Pal

Expendable Packaging in Piece Cost: $0.01 $0.00 0 $0.00 0 $2.50 2 $0.00 0 $0.00 

Packaging Cost Total: $0.010

10

38,298

47

450,000

4

1,800,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

File:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-05, 6 of 8
Bearing Elements 0590 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Bearings & Thrust Shims - Crankshaft, Part Number: 0590-N0101-01/02/03 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate 

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

Bearing - Crankshaft, 1/2 Bearing (Top) 0590-N0101-01 5 S Bearing/Shim - Crankshaft Thrust 0590-N0101-02 2 S Bearing - Crankshaft, 1/2 Bearing (Bottom) 0590-N0101-03 5 S 

0 0 0 0 0 0 0 

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

T1 or OEM Total Manufacturing Cost: $2.13 $0.00 $0.00 $2.13 $0.00 $0.00 $0.00 $0.00 

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

Base Cost Impact to Vehicle: $2.13 $0.00 $0.00 $2.13 $0.00 $0.00 $0.00 $0.00 

Packaging Calculations 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

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 

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

Expendable Packaging in Piece Cost: $0.00 $1.00 0 $3.00 0 $0.00 0 $0.00 0 $0.00 

Packaging Cost Total: $0.000

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COS

1 

450,000 

9,574

47 

450,000 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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 

File:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-05, 7 of 8
Engine Assembly-05-- Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: OEM Assembly of Cylinder Block Components to Engine Part Number: Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = Material + Labor 

+ Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

Squirter - Oil, Piston Cooler - Assembly 0504-N0101-01 4 Engine Assembly OEM Not Applicable General Assembly-OEM Mech. Assembly, HC 800 1 0.000 $0.00 $83.31 $150.19 $0.00 $0.10 $0.19 $0.29 0.00% 0.00% 0.00% 0.00% 0Squirter - Oil, Piston Cooler - Assembly 0504-N0101-01 4 Engine Assembly OEM Not Applicable General Assembly-OEM Mech. Assembly, HC 1440 1 0.000 $0.00 $83.31 $150.19 $0.00 $0.06 $0.10 $0.16 0.00% 0.00% 0.00% 0.00% 0

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

S

A

Squirter - Oil, Piston Cooler & Bolt - Piston Cooler Valve/Retainer 0504-N0101-01/02 4 SAC $Bearing Set (Upper/Lower/Thrust Shim) 0590-N0101-01/02/03 1 (UPGRADE SET) SAC $

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

Ma

T1 or OEM Total Manufacturing Cost: $10.51 $0.65 $1.17 $12.33 $0.00 $0.00 $0.00 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 8.00% 0.00% 15

(SAC) &T1 or OEM Mark-Up Values: (10.51) ----- ----- ----- $0.09 $0.86 $0.99 $0.00 $

Base Cost Impact to Vehicle: $0.00 $0.65 $1.17 $1.82 $0.09 $0.86 $0.99 $0.00 $

Packaging Calculations 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

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 

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

O

Pal

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

Packaging Cost Total: $0.000

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

1 

450,000 

9,574

47 

450,000 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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.

Pallet OptionsOption1: 48"(122cm)x45"(114cm)x34"(86cm)Investment $200 US funds (Mike S.)Assume Plastic Returnables Last 5 YearsOption2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)Investment $20K for toolPiece Price, Pallet Base $100/BasePiece Price, Tier Pad $40/PadCardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

File:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-05, 8of 8
Appendix G.1 - Subsystem 06

Cylinder Head Subsystem

 Case Study #0101

MAQS Worksheets

File:Cylinder Head 06, 032009-2.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-06, 1 of 8
Cylinder Head 0601 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Cylinder Head Assembly - Machined w. Studs, Plugs, etc. Part Number: 0601-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

1A Cylinder Head - Machined w/o. Studs, Valves, etc. 0601-N0101-01 1 Cylinder head machining, plug assembly & test OEM Not Applicable CNC Operator-OEM CNC Milling, LS, HC 83 0.25 0.000 $0.00 $68.07 $250.00 $0.00 $0.21 $3.03 $3.24 0.00% 0.00% 0.00% 0.00% 0

1B Cylinder Head - Heat Treat 0601-N0101-02 1

T6 Heat Treat, only consider solution step (quench and artificial age for T6 and T5 approx. estimated to have same cost impact)

OEM Not Applicable Heat Treat Operator-OEM Heat Treat, MLS, MHC 81 0.25 0.000 $0.00 $137.35 $250.00 $0.00 $0.42 $3.08 $3.50 0.00% 0.00% 0.00% 0.00% 0

1C

Cylinder Head Subassembly - CastMini Cooper

0601-N0101-02-01 1 Cylinder head casting & rough machining OEM Aluminum-356-T6, Cast Not Applicable Not Applicable 89 0 29.01 $1.20 $0.00 $0.00 $34.81 $0.00 $0.00 $34.81 5.00% 0.00% 0.00% 0.00% 5

1D

Cylinder Head Subassembly - CastChrysler

0601-N0101-02-01 1 Cylinder head casting & rough machining OEM Aluminum-A319-T5, Cast Not Applicable Not Applicable 89 0 -30.99 $1.15 $0.00 $0.00 -$35.64 $0.00 $0.00 -$35.64 0.00% 0.00% 0.00% 0.00% 0

0 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0

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

S

A

0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

1 

450,000 

9,574

47 

450,000 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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.

Mini Cooper Head = 30.33- (M8x60 studs x 15 ) 0.69 - Back Support Cap 0.61 = 29.03lbsChrysler GEMA Head = 30.64 - (Valve Guides Intake and Exhaust) 0.53 - (2 M8 Studsx80) 0.12 and (2 M10 Studs x60) 0.15 + (Timing Chain Cover Contribution) 1.15 = 29.84

Assume casting speed for Chrysler and Mini Cooper Heads will be approximately the same. Thus no additional Labor or Burden costs were accounted for.

5% Added Scrap Cost For A356 

File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-06, 2 of 8
Cylinder Head 0601 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Cylinder Head Assembly - Machined w. Studs, Plugs, etc. Part Number: 0601-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

1 

450,000 

9,574

47 

450,000 

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

Ma

T1 or OEM Total Manufacturing Cost: -$0.83 $0.63 $6.11 $5.91 $1.74 $0.00 $0.00 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 8.00% 0.00% 15

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.05 $0.54 $0.61 $0.00 $

Base Cost Impact to Vehicle: -$0.83 $0.63 $6.11 $5.91 $1.79 $0.54 $0.61 $0.00 $

Packaging Calculations 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

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 0.00% $0 0 1 

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

O

Pal

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

Packaging Cost Total: $0.000

File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-06, 3 of 8
Valve Seat 0602 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Seat - Intake Valve, Seat - Exhaust Valve, Part Number: 0602-N0101-03/04 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

S

A

1A Seat - Intake Valve 0602-N0101-03 8 Material difference S $2A Seat - Exhaust Valve 0602-N0101-04 8 Material difference S $

$

0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $

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

Ma

T1 or OEM Total Manufacturing Cost: $0.34 $0.00 $0.00 $0.34 $0.00 $0.00 $0.00 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0

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

Base Cost Impact to Vehicle: $0.34 $0.00 $0.00 $0.34 $0.00 $0.00 $0.00 $0.00 $

Packaging Calculations 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

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 36,000,000 60 0.00% $0 0 1 

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

O

Pal

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

Packaging Cost Total: $0.000

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

8 

3,600,000 

76,596

47 

450,000 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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.

Absolute Cost for Premium Valve SeatsIntake Valve, COMO 1207 => $0.18/ValveExhaust Valve, AR20 => $0.25/ValveBenchmark data from Munro on Baseline Intake and Exhaust Valve Seat $0.16 and $0.22

SETS

File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-06, 4 of 8
Bearing Caps 0606 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Cap, Head (Fuel Pump & Vacuum Mount) Part Number: 0606-N0101-03 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

1A Cap, Head (Fuel Pump & Vacuum Mount) 0606-N0101-03-01 1 CNC Machining S Not Applicable Mold/Cast/Sinter Operator Diecast, LMC 240 0.5 0.000 $0.00 $43.52 $100.05 $0.00 $0.09 $0.42 $0.51 0.00% 0.00% 0.00% 0.00% 01B Cap, Head (Fuel Pump & Vacuum Mount) 0606-N0101-03-02 1 Die casting S Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC 240 0.5 0.610 $1.10 $43.52 $100.05 $0.67 $0.09 $0.42 $1.18 0.00% 0.00% 0.00% 0.00% 0

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

Ma

T1 or OEM Total Manufacturing Cost: $0.67 $0.18 $0.83 $1.69 $0.00 $0.00 $0.00 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.11 $0.10 $0.04 $

Base Cost Impact to Vehicle: $0.67 $0.18 $0.83 $1.69 $0.01 $0.11 $0.10 $0.04 $

Packaging Calculations 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

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.032 $64,079 0.00% 2,250,000 60 5.00% $5,140 12 4608 

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

O

Pal

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

Packaging Cost Total: $0.032

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

1 

450,000 

9,574

47 

450,000 

File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3 Appnedix G.1-06, 5 of 8
Sealing Elements 0685 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Gasket - Cylinder Head to Block Part Number: 0685-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

S

A

Gasket - Cylinder Head to Block 0685-N0101-01 1 Change from 2 to 3 layer gasket S $

0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $

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

Ma

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

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0

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

Base Cost Impact to Vehicle: $1.46 $0.00 $0.00 $1.46 $0.00 $0.00 $0.00 $0.00 $

Packaging Calculations 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

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 

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

O

Pal

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

Packaging Cost Total: $0.000

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

1 

450,000 

9,574

47 

450,000 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-06, 6 of 8
Engine Assembly -06-- Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: OEM Assembly of Cylinder Head Components to Engine Part Number: NA Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

1A Cap, Head (Fuel Pump & Vacuum Mount)0606-N0101-03-01 1 Head and cam assembly OEM Not Applicable Not Applicable Not Applicable 150 0 0.000 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 0.00% 0.00% 0.00% 0.00% 0

1B Cap, Head (Fuel Pump & Vacuum Mount) 0606-N0101-03-01 1 Head & Cap Machining OEM Not Applicable Not Applicable Not Applicable 217 0.25 0.000 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 0.00% 0.00% 0.00% 0.00% 0

0 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 00 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0

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

S

A

1A Seat - Intake/Exhaust Valves 0602-N0101-03 8 Material difference SAC $2A Cap, Head (Fuel Pump & Vacuum Mount) 0606-N0101-03-01 1 Added Part SAC $3A Bolt - Cap Bearing, Camshaft 0680-N0101-01 4 Added Part S $4A Gasket - Cylinder Head to Block 0685-N0101-01 1 Modified Part SAC $5A Bolt - Manifold, Exhaust 0680-N0101-10 10 510 Stainless or A286 Inconel S $

0 $0 $0 $0 $0 $0 $0 $0 $0 $

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

Ma

T1 or OEM Total Manufacturing Cost: $10.11 $0.00 $0.00 $10.11 $0.00 $0.00 $0.00 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0

(SAC) &T1 or OEM Mark-Up Values: (6.19) ----- ----- ----- $0.00 $0.00 $0.00 $0.00 $

Base Cost Impact to Vehicle: $3.92 $0.00 $0.00 $3.92 $0.00 $0.00 $0.00 $0.00 $

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

1 

450,000 

9,574

47 

450,000 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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.

NOTES:Did not add any additional costs to add Cap, Head (Fuel Pump & Vacuum Mount). Assumption is additional labor& burden would be negligible in having existing automated process. Machining for O/S face of Cap, Head (Fuel Pump & Vacuum Mount) covered as part of Cylinder Head Machining.

Stainless Steel Exhaust Manifold Hanger Studs: Upgrade to Stainless: Estimated base stud $0.35 and Stainless stud $0.70310/316 (Studs on Mini are Magnetic)410 series good for high temp fastener application not recommended for use w. Aluminum due to Galvanic Action510 Series Stainless or A286 (25.5Ni/14.75Cr)

File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-06, 7 of 8
Engine Assembly -06-- Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: OEM Assembly of Cylinder Head Components to Engine Part Number: NA Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

1 

450,000 

9,574

47 

450,000 

Packaging Calculations 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

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 

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

O

Pal

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

Packaging Cost Total: $0.000

File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-06, 8 of 8
Appendix G.1 - Subsystem 07

Valve Train Subsystem

 Case Study #0101

MAQS Worksheets

File:Valve Trains 07, 032609.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-07, 1 of 4
Valves Int.0701 & Exh.0702 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Valve - Intake & Valve - Outlet Part Number: 0701-N0101-01 & 0702-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

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

Valve - Inlet 0701-N0101-01 1

Intake valves would need to be upgraded - typical upgrade would be from nitrided JIS SUH11 (Fe-1.5Si, 8.5Cr, 0.5C) to Silichrome

S 

Valve - Outlet 0702-N0101-01 1

Exhaust valves would need to be upgraded - typical upgrade would be from nitrided JIS SUH 35 (Fe, 9Mn, 21Cr 4Ni, 0.5C and 0.4N) to Inconel head and Silichrome stem. Exhaust valves on Mini Cooper Turbo DI are Sodium filled as well. This design approach is not considered preferred and thus will note be included in cost analysis.

S 

0 0 0 0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $1.08 $0.00 $0.00 $1.08 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7

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

Base Cost Impact to Vehicle: $1.08 $0.00 $0.00 $1.08 $0.01 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 36,000,000 60 5.00% $0 

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

O

Pa

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

76,596

1047

450,000

8

3,600,000

 PACKAGING CALCULATIONS: Packaging Type: NO IMPACT TO PACKAGINGPart Size:Parts/Layer:Number of Layers:

"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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both 

File:Valve Trains 07, 032609.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-07, 2 of 4
Camshafts 0706 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Camshaft - Intake Machine & Exhaust Machined Part Number: 0706-N0101-02 & 0706-N0101-11 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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 

Mutiplier

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) S

R

(

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

1A Camshaft - Intake Machined (MINI) 0706-N0101-02 1

Weight Delta between Mini and Chrysler 

GEMA camshafts. Estimate no cost impact relative to fabrication or machining. 

T1 Assembly, Mark-up Applied @ Bottom. Nodular Iron, Cast Not Applicable Not Applicable 113 1 1 1 3.886 $0.35 $0.00 $0.00 $0.00 $1.36 $0.00 $0.00 $1.36 0.00% 0

2A Camshaft - Exhaust Machined (MINI) 0706-N0101-11 1

Weight Delta between Mini and Chrysler 

GEMA camshafts. Estimate no cost impact relative to fabrication or machining. 

T1 Assembly, Mark-up Applied @ Bottom. Nodular Iron, Cast Not Applicable Not Applicable 113 1 1 1 4.256 $0.35 $0.00 $0.00 $0.00 $1.49 $0.00 $0.00 $1.49 0.00% 0

3A Camshaft - Intake Machined (MINI) 0706-B0101-02 1

Weight Delta between Mini and Chrysler 

GEMA camshafts. Estimate no cost impact relative to fabrication or machining. 

T1 Assembly, Mark-up Applied @ Bottom. Nodular Iron, Cast Not Applicable Not Applicable 113 1 1 1 -4.260 $0.35 $0.00 $0.00 $0.00 -$1.49 $0.00 $0.00 -$1.49 0.00% 0

4A Camshaft - Exhaust Machined (MINI) 0706-B0101-11 1

Weight Delta between Mini and Chrysler 

GEMA camshafts. Estimate no cost impact relative to fabrication or machining. 

T1 Assembly, Mark-up Applied @ Bottom. Nodular Iron, Cast Not Applicable Not Applicable 113 1 1 1 -4.630 $0.35 $0.00 $0.00 $0.00 -$1.62 $0.00 $0.00 -$1.62 0.00% 0

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

0 

0 0 0 0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: -$0.26 $0.00 $0.00 -$0.26 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 5.00% 6

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

Base Cost Impact to Vehicle: -$0.26 $0.00 $0.00 -$0.26 -$0.01 -

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 

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

O

Pa

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: Packaging Type: NO IMPACT TO PACKAGINGPart Size:Parts/Layer:Number of Layers:

"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.

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

File:Valve Trains 07, 032609.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-07, 3 of 4
Engine Assembly 0700 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Engine Assembly Impact from upgraded Valve Train components Part Number: 0700 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

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

0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 

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

1A Valves Intake and Exhaust Delta (Mini$-Chrysler$) 8 SAC 

2A Camshafts Exhaust & Intake Delta (Mini$-Chrysler$) 1 SAC 

0 0 0 0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $10.06 $0.00 $0.00 $10.06 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

(SAC) &T1 or OEM Mark-Up Values: (10.06) ----- ----- ----- $0.00 

Base Cost Impact to Vehicle: $0.00 $0.00 $0.00 $0.00 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 

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

O

Pa

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: Packaging Type:Part Size:Parts/Layer:Number of Layers:

"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.

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

No engine assembly cost impact as a result of valve train upgrades.

File:Valve Trains 07, 032609.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-07, 4 of 4
Appendix G.1 - Subsystem 08

Timing Drive Subsystem

 Case Study #0101

MAQS Worksheets

File:Timing Drives 08 032608.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-08, 1 of 2
Timing Wheels 0801 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Sprocket - Crankshaft, Timing Drive Part Number: 0801-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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 

Mutiplier

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) S

R

(

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

Sprocket - Crankshaft, Timing Drive 0801-N0101-01 1 (Smart Sprocket royalty, mark- ups included) S 

0 0 0 0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $1.60 $0.00 $0.00 $1.60 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

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

Base Cost Impact to Vehicle: $1.60 $0.00 $0.00 $1.60 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 

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

O

Pa

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

Packaging Cost Total: $0.000

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

 PACKAGING CALCULATIONS: Packaging Type: No Change to PackagingPart Size:Parts/Layer:Number of Layers:

"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.

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

File:Timing Drives 08 032608.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-08, 2 of 2
Appendix G.1 - Subsystem 10

Intake Subsystem

 Case Study #0101

MAQS Worksheets

File:Intake Systems 10 032609.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-10, 1 of 2
Intake Manifold 1001 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Manifold Assembly - Intake Part Number: 1001-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

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

1A Manifold - Intake, Bottom Half (Mini) 1001-N0101-01-07 1 Injection Molding T1 Assembly, Mark-up Applied @ Bottom. Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS 254 0.5 1 1 1.408 $1.76 $43.52 $150.01 $150.01 $2.48 $0.09 $0.59 $3.15 0.00% 01B Manifold - Intake, Top Half (Mini) 1001-N0101-01-06 1 Injection Molding T1 Assembly, Mark-up Applied @ Bottom. Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS 267 0.5 1 1 0.949 $1.76 $43.52 $150.01 $150.01 $1.67 $0.08 $0.56 $2.31 0.00% 0

0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 

1A Manifold - Intake, Bottom Half (Chrysler) 1001-B0101-01-07 1 Injection Molding T1 Assembly, Mark-up Applied @ Bottom. Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS -226 0.5 1 1 -5.036 $1.76 $43.52 $150.01 $150.01 -$8.86 -$0.10 -$0.67 -$9.62 0.00% 01B Manifold - Intake, Top Half (Chrysler) 1001-B0101-01-06 1 Injection Molding T1 Assembly, Mark-up Applied @ Bottom. Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS -255 0.5 1 1 -3.380 $1.76 $43.52 $150.01 $150.01 -$5.95 -$0.09 -$0.59 -$6.62 0.00% 0

0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: -$10.66 -$0.01 -$0.10 -$10.78 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- -$0.05 -

Base Cost Impact to Vehicle: -$10.66 -$0.01 -$0.10 -$10.78 -$0.05 -

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.362 $723,404 0.00% 2,250,000 60 5.00% $340 

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

O

Pa

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

Packaging Cost Total: $0.362

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: MINI COOPER INTAKE MANIFOLD = $0.08Packaging Type: Option #2Part Size: 370x280x170Parts/Layer: 4 x 3 =12Number of Layers: 5

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

Equipment, Tooling and Fixturing for friction welding top and bottom sections of intake manifold together would be less expensive for Mini versus GEMA. However since time and burden rate differences would be minor, we have not included the difference as a line code in the quote.

 PACKAGING CALCULATIONS: CHRYSLER GEMA INTAKE MANIFOLD = $0.36Packaging Type: Option #2Part Size: 370x380x225Parts/Layer: 3 x 3Number of Layers:3

File:Intake Systems 10 032609.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-10, 2 of 2
Appendix G.1 - Subsystem 11

Fuel Induction Subsystem

 Case Study #0101

MAQS Worksheets

File:Fuel Induction 11 032709.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-11, 1 of 12
Fuel Rail-1101-R5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Fuel Rail - High Pressure Part Number: 1101-N0101-02 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

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

Fuel Rail High Pressure 1101-N0101-02 1 Assembly, Braze & Test T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 288 3 1 10 0.000 $0.00 $35.51 $15.00 $150.00 $0.00 $0.37 $0.52 $0.89 0.00% 0

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube - Injector Rail 1101-N0101-02-06 1 Turn & cross Drill T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Tube CNC Operator CNC Turning, MC 180 0.5 1 1 0.600 $1.65 $35.70 $45.00 $45.00 $0.99 $0.10 $0.25 $1.34 0.00% 02A Threaded Plug Rail Inlet 1101-N0101-02-05 1 Machine & Tap T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Bar CNC Operator CNC Turning, MC 138 1 1.5 1 0.060 $1.65 $35.70 $45.00 $67.50 $0.10 $0.26 $0.49 $0.84 0.00% 03A Boss High Pressure Sensor 1101-N0101-02-03 1 Machine & Tap T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Bar CNC Operator CNC Turning, LMC 164 0.5 1.5 1 0.080 $1.65 $35.70 $100.00 $150.00 $0.13 $0.11 $0.92 $1.16 0.00% 04A Cup Injector Port 1101-N0101-02-01 4 Plating T1 Assembly, Mark-up Applied @ Bottom. Plating, Fuel Rail Plating/Coating Operator Plate/Finish, SMS, MHC 720 1 1 1 0.001 $20.00 $55.17 $125.17 $125.17 $0.02 $0.08 $0.17 $0.27 0.00% 04B Cup Injector Port 1101-N0101-02-01-1 4 Machine & Cross Drill T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Bar CNC Operator CNC Turning, HC 480 2 4 1 0.260 $1.65 $35.70 $75.00 $300.00 $0.43 $0.15 $0.63 $1.20 0.00% 05A Bracket Rail Mounting 1101-N0101-02-02 2 Stamping T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 610 0.5 1 1 0.147 $1.64 $42.18 $100.10 $100.10 $0.24 $0.03 $0.16 $0.44 0.00% 0

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

1A Plug Rail End 1101-N0101-02-04 1 Stainless 304 S 

2A High Pressure Fuel Sensor Assembly 1101-N0101-03 1 Pressure Sensor S 

0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $11.09 $1.81 $5.70 $18.59 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.06 

Base Cost Impact to Vehicle: $11.09 $1.81 $5.70 $18.59 $0.06 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.068 $136,636 0.00% 2,250,000 60 5.00% $2,740 

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

O

Pa

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

Packaging Cost Total: $0.068

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: Packaging Type: Option #3, Tote w. Vacuum Form PackPart Size: 300x55x100mmParts/Layer: 8Number of Layers:3

"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.

Full Quote Modification Differential Quote (Quote Summary includes 

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 2 of 12
Injector-1104-R5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Fuel Injector Assembly - Solenoid, 7 Hole Part Number: 1104-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

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

1A Fuel Injector Assembly 1104-N0101-01 1 Final Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Mech Assembly, LC, Base 480 2 1 6 0.000 $0.00 $37.35 $15.00 $90.00 $0.00 $0.16 $0.19 $0.34 0.00% 2A Seal Injector Tip 1104-N0101-01-30 1 Overmold seal @ Injector Tip T1 Assembly, Mark-up Applied @ Bottom. Nylon-HT, Inject. Electromechanical Assembly Mech Assembly, MC, Base 450 1 1 1 0.005 $4.00 $37.35 $30.00 $30.00 $0.02 $0.08 $0.07 $0.17 0.00% 3A Solenoid Body preassembled 1104-N0101-01-10 1 Insert Windings, Ring Locator and Needle Body Assembly into Body Injector and Overmold T1 Assembly, Mark-up Applied @ Bottom. Nylon66-40FMR, Inject. Electromechanical Assembly Mech Assembly, HC, Base 450 2 1 5 0.030 $1.54 $37.35 $45.00 $225.00 $0.05 $0.17 $0.50 $0.71 0.00% 4A Needle Body Assembly 1104-N0101-01-50 1 Laser weld internal valve body (Sleeve, Needle Body, Tip and Inlet Tube) T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Mech Assembly, MC, Base 450 4 1.5 8 0.000 $0.00 $37.35 $30.00 $360.00 $0.00 $0.33 $0.80 $1.13 0.00% 5A Needle Assembly 1104-N0101-01-11 1 Assemble & Press Sleeve T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Mech Assembly, MC, Base 450 1 1 4 0.000 $0.00 $37.35 $30.00 $120.00 $0.00 $0.08 $0.27 $0.35 0.00% 6A Needle Injector 1104-N0101-01-13 1 Laser Weld Ball and Seat to Needle T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Mech Assembly, MC, Base 514 1 1 3 0.000 $0.00 $37.35 $30.00 $90.00 $0.00 $0.07 $0.18 $0.25 0.00% 7A Metering Valve assembly 1104-N0101-01-16 1 Laser Weld Plate to Valve T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Mech Assembly, MC, Base 514 1 1 2 0.000 $0.00 $37.35 $30.00 $60.00 $0.00 $0.07 $0.12 $0.19 0.00% 

0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 

Purchase Part - High Impact Item (Full Cost Mapping)

1A Body Injector Solenoid 1104-N0101-01-20 1 Machine Body T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC 500 0.5 5 1 0.140 $4.56 $35.70 $45.00 $225.00 $0.64 $0.04 $0.45 $1.12 0.50% 2A Sleeve winding to inlet separator 1104-N0101-01-27 1 Machine and Roll Splines T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC 491 0.5 4.5 1 0.074 $4.56 $35.70 $45.00 $202.50 $0.34 $0.04 $0.41 $0.79 0.50% 3A Sleeve Fuel Inlet 1104-N0101-01-28 1 Machine T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC 485 0.5 3.5 1 0.041 $4.56 $35.70 $45.00 $157.50 $0.19 $0.04 $0.33 $0.55 0.50% 4A Body needle 1104-N0101-01-9 1 Machine and Roll Splines T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC 460 0.5 5.5 1 0.043 $4.56 $35.70 $45.00 $247.50 $0.20 $0.04 $0.54 $0.77 0.50% 5A Inlet Tube 1104-N0101-01-21 1 Cut and Flare T2/T3 Hydro/CNC Form, SSLC S-Steel-304, Tube Forging Operator Cold Forge, LMC 360 0.5 1 1 0.010 $1.65 $38.52 $100.09 $100.09 $0.02 $0.05 $0.28 $0.35 0.30% 6A Spring Seat Lower 1104-N0101-01-14 1 Machine T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC 450 0.25 1.5 1 0.0002 $4.56 $35.70 $45.00 $67.50 $0.00 $0.02 $0.15 $0.17 0.50% 7A Needle valve 1104-N0101-01-24 1 Centerless Grind T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, MC 540 0.25 1.5 1 0.000 $0.00 $35.70 $45.00 $67.50 $0.00 $0.02 $0.13 $0.14 0.50% 7B Needle valve 1104-N0101-01-24-01 1 Machine Heat Treat T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC 540 0.25 1.5 1 0.002 $4.56 $35.70 $45.00 $67.50 $0.01 $0.02 $0.13 $0.15 0.50% 8A Ball Needle seat 1104-N0101-01-23 1 EDM Mounting Pocket T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, MC 720 0.25 1 1 0.000 $0.00 $35.70 $45.00 $45.00 $0.00 $0.01 $0.06 $0.07 0.50% 8A Ball Needle seat 1104-N0101-01-23 1 Grind/Lap/Wash T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, MC 540 0.25 1.5 1 0.000 $0.00 $35.70 $45.00 $67.50 $0.00 $0.02 $0.13 $0.14 0.50% 8A Ball Needle seat 1104-N0101-01-23 1 Cold Head/Machine/Heat Treat T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator Cold Forge, LMC 720 0.25 1 1 0.0003 $4.56 $35.70 $100.09 $100.09 $0.00 $0.01 $0.14 $0.15 0.50% 9A Metering Valve 1104-N0101-01-18 1 Machined T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC 470 0.25 3 1 0.005 $4.56 $35.70 $45.00 $135.00 $0.02 $0.02 $0.29 $0.33 0.50% 

10A Plate Metering Valve 1104-N0101-01-19 1 Stamping T2/T3 Stamp/Form, MSMC S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 766 0.25 1 1 0.0002 $1.64 $42.18 $100.10 $100.10 $0.00 $0.01 $0.13 $0.14 0.50% 11A Tip - Injector 1104-N0101-01-08 1 EDM Micro Popping T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Milling, MHC 480 0.5 2 1 0.000 $0.00 $35.70 $150.15 $300.30 $0.00 $0.04 $0.63 $0.66 0.50% 11B Tip - Injector 1104-N0101-01-08-01 1 Metal Injection Molding T2/T3 Powder Metal, LSHC S-Steel-440-MIM Mold/Cast/Sinter Operator Powder Metal, MHC 480 1 1 1 0.002 $13.68 $43.52 $150.14 $150.14 $0.03 $0.09 $0.31 $0.43 0.70% 12A Face seal Injector to head 1104-N0101-01-4-1 1 Powder Metal T2/T3 Powder Metal, SSLC PM-SMF-SS410 Mold/Cast/Sinter Operator Powder Metal, LMC 1440 0.5 1 1 0.005 $4.92 $43.52 $100.14 $100.14 $0.02 $0.02 $0.07 $0.11 0.30% 13A Bracket Injector hold-down 1104-N0101-01-2 1 Stamping T2/T3 Stamp/Form, MSMC HC-Steel-4130, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 600 0.5 1 1 0.078 $0.78 $42.18 $100.10 $100.10 $0.06 $0.04 $0.17 $0.26 0.50% 

0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 

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

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

1A Solenoid Windings 1104-N0101-01-22 1 S 

2A Ring winding locator 1104-N0101-01-26 1 S 3A Spring - needle to metering valve 1104-N0101-01-15 1 S 4A Spring Needle Return 1104-N0101-01-12 1 S 5A Sleeve Screen Stop 1104-N0101-01-25 1 S 6A Screen Fuel Inlet 1104-N0101-01-6 1 S 7A circlip face seal retainer 1104-N0101-01-5 1 S 8A Compression limiter - oring 1104-N0101-01-3 1 S 9A O-Ring Injector to rail seal 1104-N0101-01-1 1 S 

0 0 0 0 

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

38,298

1047

450,000

4

1,800,000

"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.

Full Quote Modification Quote Differential Quote (Quote Summary includes 

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 3 of 12
Injector-1104-R5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Fuel Injector Assembly - Solenoid, 7 Hole Part Number: 1104-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

38,298

1047

450,000

4

1,800,000

Full Quote Modification Quote Differential Quote (Quote Summary includes 

Material Labor Burden TMC Scrap 

T1 or OEM Total Manufacturing Cost: $2.16 $1.47 $6.44 $10.07 $0.03 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.08 

Base Cost Impact to Vehicle: $2.16 $1.47 $6.44 $10.07 $0.11 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces/ 

Amortization 

Period

Number of 

Service Months 

Interest 

Rate

Cost per Pallet /Rack

Rack/Pallet Investment Amortization: $0.014 $108,680 0.00% 9,000,000 60 5.00% $4,180 

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

P

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

Packaging Cost Total: $0.014

 PACKAGING CALCULATIONS: Packaging Type: Option #3 Tote, 42 Totes/PalletPart Size: 90x55x25 mmParts/Layer per tote: 3 x 8Number of Layers per tote: 9

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 4 of 12
HP-Fuel Pump 1107-R5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Fuel Pump - High Pressure w. Vol.Control Valve (Driven-Off Intake Cam) Part Number: 1107-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

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

1A Fuel Pump - High Pressure w. Vol. Control Valve 1107-N0101-01 1 Final Assembly Line T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, HC, Base 360 3 1 10 0.250 $0.00 $35.51 $45.00 $450.00 $0.00 $0.30 $1.25 $1.55 0.00% 02A Swash Plate Drive Assembly 1107-N0101-01-09 1 Subassembly Line T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 360 1 1 8 0.000 $0.00 $35.51 $30.00 $240.00 $0.00 $0.10 $0.67 $0.77 0.00% 03A Bellow piston cavity 1107-N0101-01-14 2 Weld Subassembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 300 2 1 4 0.000 $0.00 $35.51 $30.00 $120.00 $0.00 $0.24 $0.40 $0.64 0.00% 04A Bellow Retainer 1107-N0101-01-16 2 Press Orifice Insert onto Bellows Retainer T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 600 1 1 1 0.000 $0.00 $35.51 $30.00 $30.00 $0.00 $0.06 $0.05 $0.11 0.00% 05A Shaft Drive Adapter 1107-N0101-01-09-6 1 Press Ball, Springs and Insert T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 300 0.5 1 1 0.000 $0.00 $35.51 $30.00 $30.00 $0.00 $0.06 $0.10 $0.16 0.00% 0

Purchase Part - High Impact Item (Full Cost Mapping)

1A Housing Fuel Pump 1107-N0101-01-25-1 1 Extrude Housing T2/T3 Cold Forge, MSMC Aluminum-7075-T6, Ext. Extruding/Drawing Operator Cold Forge, MHC 96 2 1 1 1.800 $3.21 $54.35 $150.09 $150.09 $5.78 $1.13 $1.56 $8.47 0.50% 61B Housing Fuel Pump 1107-N0101-01-25-1 1 Machine Housing T2/T3 CNC Milling, LSHC Not Applicable CNC Operator CNC Machining, LMC 121 4 14 1 0.000 $0.00 $35.70 $25.00 $350.00 $0.00 $1.18 $2.88 $4.06 0.70% 7

1C Housing Fuel Pump 1107-N0101-01-25 1 Assemble Ball Plugs T2/T3 Mech. Assembly, SSLC Purchased Parts General Assembly

Mech Assembly, LC, Base

240 1 1 4 0.110 $1.00 $35.51 $15.00 $60.00 $0.11 $0.15 $0.25 $0.51 0.30% 6

2A Bar Stock - Check Valve Assembly 1107-N0101-01-22-1 1 Machining T2/T3 CNC Turning, SSLC S-Steel-304, Bar Lathe/Turning Operator S-CNC Turning, HC 180 0.25 2 1 0.040 $1.65 $37.60 $85.00 $170.00 $0.07 $0.05 $0.94 $1.06 0.30% 62B Check Valve Assembly 1107-N0101-01-22 1 Assemble components T2/T3 Mech. Assembly, SSLC Purchased Parts General Assembly Mech Assembly, MC, Base 277 1 1 2 0.030 $1.00 $35.51 $30.00 $60.00 $0.03 $0.13 $0.22 $0.37 0.30% 63A Retainer Check Valve Assembly 1107-N0101-01-24-1 1 Machining T2/T3 CNC Turning, SSLC Ni-Al-Bronze-630000, Bar Lathe/Turning Operator CNC Turning, LC 144 1 2 1 0.075 $2.44 $37.60 $25.00 $50.00 $0.18 $0.26 $0.35 $0.79 0.30% 64A Plate - Check Valve 1107-N0101-01-20 2 Machining T2/T3 CNC Turning, SSLC S-Steel-304, Bar Lathe/Turning Operator CNC Turning, LC 257 0.5 2 2 0.000 $1.65 $37.60 $25.00 $100.00 $0.00 $0.07 $0.39 $0.46 0.30% 65A Seat - Check Valve Plate 1107-N0101-01-21 2 Machining T2/T3 CNC Turning, SSLC S-Steel-304, Bar Lathe/Turning Operator S-CNC Turning, MC 250 1 2.5 1 0.005 $1.65 $37.60 $55.00 $137.50 $0.01 $0.15 $0.55 $0.71 0.30% 66A Retainer Check Valve 1107-N0101-01-17 2 Machining T2/T3 CNC Turning, SSLC S-Steel-316, Bar Lathe/Turning Operator S-CNC Turning, HC 251 1 3 1 0.050 $2.44 $37.60 $85.00 $255.00 $0.12 $0.15 $1.02 $1.29 0.30% 67A Bellow piston cavity 1107-N0101-01-14-1 2 Cut and Form Tube Stock T2/T3 Hydro/CNC Form, MSMC Titanium-6AL4V, Bar Cut/Punch/Forming Operator Hydro/CNC Form, MLS, MHC 225 1 1 1 0.010 $34.37 $42.18 $150.12 $150.12 $0.34 $0.19 $0.67 $1.20 5.00% 68A Spring Seat 1107-N0101-01-14-2 2 Machining T2/T3 CNC Turning, SSLC S-Steel-316, Bar Lathe/Turning Operator S-CNC Turning, MC 235 1 3 1 0.050 $2.44 $37.60 $55.00 $165.00 $0.12 $0.16 $0.70 $0.98 0.30% 69A Top Seat and Sealing Flange 1107-N0101-01-14-3 2 Machining T2/T3 CNC Turning, SSLC S-Steel-316, Bar Lathe/Turning Operator S-CNC Turning, MC 230 1 3 1 0.110 $2.44 $37.60 $55.00 $165.00 $0.27 $0.16 $0.72 $1.15 0.30% 6

10A Bellow Retainer 1107-N0101-01-16-1 2 Machining T2/T3 CNC Turning, SSLC A-Steel-41XXS, Bar Lathe/Turning Operator S-CNC Turning, MC 231 2 5 1 0.500 $0.78 $37.60 $55.00 $275.00 $0.39 $0.33 $1.19 $1.91 0.30% 611A Piston High pressure pump 1107-N0101-01-11 2 Machining T2/T3 CNC Turning, SSLC A-Steel-4140, Bar Lathe/Turning Operator S-CNC Turning, MC 225 2 4 1.5 0.030 $0.78 $37.60 $55.00 $330.00 $0.02 $0.33 $1.47 $1.82 0.30% 612A Cap Piston contact to swash plate 1107-N0101-01-10 2 Plating T2/T3 Plate/Finish Mech., SSLC Not Applicable Plating/Coating Operator Plate/Finish, SMS, LMC 360 0.5 1 1 0.000 $0.00 $55.17 $100.17 $100.17 $0.00 $0.08 $0.28 $0.35 0.30% 612B Cap Piston contact to swash plate 1107-N0101-01-10 2 Machining T2/T3 CNC Turning, SSLC A-Steel-4140, Bar Lathe/Turning Operator S-CNC Turning, MC 225 1 2 1.5 0.000 $0.78 $37.60 $55.00 $165.00 $0.00 $0.17 $0.73 $0.90 0.30% 613A Casting: Swash Plate Drive Housing 1107-N0101-01-09-2 1 Aluminum Diecast T2/T3 Diecast, SSLC Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC 286 0.5 1 1 0.209 $1.10 $43.52 $100.05 $100.05 $0.23 $0.08 $0.35 $0.66 5.00% 613A Swash Plate Drive Housing Machined 1107-N0101-01-09-1 1 Machine Casting T2/T3 CNC Turning, MSMC Not Applicable Mold/Cast/Sinter Operator RTM Turning, HC, PP, Base 300 0.5 1 1 0.000 $0.00 $43.52 $200.00 $200.00 $0.00 $0.07 $0.67 $0.74 0.50% 614A Swash Plate Assy - Cast 1107-N0101-01-09-5-3 1 Iron Casting T2/T3 Perm. Cast, MSMC Nodular Iron, Cast Mold/Cast/Sinter Operator Perm. Cast, MHC 286 3 1 1 0.219 $0.35 $43.52 $150.06 $150.06 $0.08 $0.46 $0.53 $1.06 5.00% 614B Swash Plate Assy 1107-N0101-01-09-5-2 1 Machine Casting T2/T3 CNC Turning, MSMC Not Applicable CNC Operator RTM Turning, HC, PP, Base 360 0.5 1 1.2 0.000 $0.00 $35.70 $200.00 $240.00 $0.00 $0.05 $0.67 $0.72 0.50% 6

14C Swash Plate Assy 1107-N0101-01-09-5-1 1 Heat Treat T2/T3 Plate/Finish Mech., SSLC Not Applicable Heat Treat Operator Heat Treat, SMS, MHC 250 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.19 $0.40 $0.59 0.30% 614D Swash Plate Assy 1107-N0101-01-09-5 1 Grind T2/T3 CNC Turning, MSMC Not Applicable CNC Operator

CNC Turning, MC

124 1 1 1 0.000 $0.00 $35.70 $45.00 $45.00 $0.00 $0.29 $0.36 $0.65 0.50% 6

15A Shaft Drive Adapter PM 1107-N0101-01-09-6-5 1 Press and Sinter T2/T3 Powder Metal, SSLC PM-SMF-Iron Base Mold/Cast/Sinter Operator Powder Metal, LMC 632 1 1 1 0.037 $1.00 $43.52 $100.14 $100.14 $0.04 $0.07 $0.16 $0.26 0.30% 615B Shaft Drive Adapter w/out backlash adjuster 1107-N0101-01-09-6-1 1 Machining T2/T3 CNC Milling, SSLC Not Applicable Mold/Cast/Sinter Operator CNC Machining, LMC 200 0.25 1 2 0.000 $0.00 $43.52 $25.00 $50.00 $0.00 $0.05 $0.25 $0.30 0.30% 617A Mount Bracket HP fuel Pump 1107-N0101-01-03 1 Ground Flat T2/T3 CNC Milling, SSLC Not Applicable Cut/Punch/Forming Operator Fine blank, LMC 600 1 1 1 0.000 $0.00 $42.18 $100.13 $100.13 $0.00 $0.07 $0.17 $0.24 0.30% 617B Mount Bracket HP fuel Pump 1107-N0101-01-03-1 1 Fineblanked T2/T3 Fine Blank, SSLC MC-Steel-1000S, Coil Cut/Punch/Forming Operator Fine blank, LMC 391 0.5 1 1 1.080 $0.55 $42.18 $100.13 $100.13 $0.59 $0.05 $0.26 $0.90 0.30% 618A Spacer - Mount Bracket - swash plate retainer 1107-N0101-01-02 1 Fineblanked T2/T3 Fine Blank, SSLC Not Applicable Cut/Punch/Forming Operator Fine blank, LMC 600 1 1 1 0.000 $0.00 $42.18 $100.13 $100.13 $0.00 $0.07 $0.17 $0.24 0.30% 618B Spacer - Mount Bracket 1107-N0101-01-02-1 1 Fineblanked T2/T3 Fine Blank, SSLC MC-Steel-1000S, Coil Cut/Punch/Forming Operator Fine blank, LMC 439 0.5 1 1 0.557 $0.55 $42.18 $100.13 $100.13 $0.31 $0.05 $0.23 $0.58 0.30% 619A Diaphragm Temperature Compensating 1107-N0101-01-08 1 Assemble & Test T2/T3 Mech. Assembly, SSLC Purchased Parts Cut/Punch/Forming Operator Mech Assembly, LC, Base 300 1 1 3 0.120 $1.00 $42.18 $15.00 $45.00 $0.12 $0.14 $0.15 $0.41 0.30% 619B Top Stamping Diaphragm Temperature Compensating 1107-N0101-01-08-1 1 Form & Stamp T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 621 0.5 1 1 0.042 $0.45 $42.18 $100.10 $100.10 $0.02 $0.03 $0.16 $0.21 0.30% 6

19C Bottom Stamping Diaphragm Temperature Compensating 1107-N0101-01-08-2 1 Form & Stamp T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 643 0.5 1 1 0.018 $0.45 $42.18 $100.10 $100.10 $0.01 $0.03 $0.16 $0.20 0.30% 6

20A Fitting Fuel Inlet 1107-N0101-01-06 1 Machine T2/T3 CNC Turning, SSLC S-Steel-304, Bar Lathe/Turning Operator S-CNC Turning, MC 123 0.5 1.5 1 0.120 $1.65 $37.60 $55.00 $82.50 $0.20 $0.15 $0.67 $1.02 0.30% 6

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

Full Quote Modification Differential Quote (Quote Summary includes 

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 5 of 12
HP-Fuel Pump 1107-R5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Fuel Pump - High Pressure w. Vol.Control Valve (Driven-Off Intake Cam) Part Number: 1107-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

Full Quote Modification Differential Quote (Quote Summary includes 

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

1A 4mm Ball Plug NA 7 Purchase Part B1A 

2A Seat Fuel Outlet Fitting NA 1 Purchase Part B1A 3A Check Ball 1107-N0101-01-22-3 1 Purchase Part B3A 4A Spring Check Ball 1107-N0101-01-22-4 1 Purchase Part B3A 5A Seat Check Ball 1107-N0101-01-22-5 1 Purchase Part B3A 6A Spring Check Valve 1107-N0101-01-23 1 Purchase Part S 7A Seat Check valve spring 1107-N0101-01-18 2 Purchase Part S 8A Spring - Check Valve 1107-N0101-01-19 2 Purchase Part S 9A Spring Bellow return 1107-N0101-01-13 2 Purchase Part S 

10A Pin Guide Pin Guide 2 Purchase Part S 11A O-Ring Bellow OD sealing 1107-N0101-01-15 2 Purchase Part S 12A Tip Insert - Orifice 1107-N0101-01-16-2 2 Purchase Part S 13A Spring HP piston 1107-N0101-01-12 2 Purchase Part S 14A Seal Swash Plate shaft 1107-N0101-01-09-4 1 Purchase Part S 15A Bearing Roller, Swash Plate Shaft 1107-N0101-01-09-8 1 Purchase Part S 16A Bearing Roller Thrust, Swash Plate 1107-N0101-01-09-7 1 Purchase Part S 17A Spring Backlash adjust 1107-N0101-01-09-6-4 2 Purchase Part S 18A Ball Backlash Adjust 1107-N0101-01-09-6-3 2 Purchase Part S 19A Ball Seat/Retainer 1107-N0101-01-09-6-2 2 Purchase Part S 20A O-ring OD Seal to pump housing 1107-N0101-01-09-3 1 Purchase Part S 21A Bolt Mount bracket 1107-N0101-01-01 3 Purchase Part S 22A Oil Swash Plate cavity 1107-N0101-01-26 1 Purchase Part S 23A Spring Stamping Diaphragm Temperature Compensating 1107-N0101-01-08-3 1 Purchase Part B19A 23B Diaphragm Temperature Compensating 1107-N0101-01-08-3-1 1 Purchase Part B19A 

24 Screen Fuel Inlet 1107-N0101-01-07 1 Purchase Part S 25 Solenoid Fuel Pump Control 1107-N0101-01-05 1 Purchase Part S 26 Bolt Control Solenoid - fuel pump 1107-N0101-01-04 2 Purchase Part S 27 Seal - High Pressure Fuel Pump to Cylinder Head 1185-N0101-01 1 Purchase Part S 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $16.99 $8.24 $28.32 $53.55 $0.33 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.41 

Base Cost Impact to Vehicle: $16.99 $8.24 $28.32 $53.55 $0.73 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.111 $221,160 0.00% 2,250,000 60 5.00% $3,880 

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

O

Pa

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

Packaging Cost Total: $0.111

 PACKAGING CALCULATIONS: Packaging Type: Option #3 TotesPart Size: 100x100x100Parts/Layer: 4x2Number of Layers: 3

"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:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 6 of 12
Pipe Assembly 1170-R5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Pipe Assembly - Fuel, High Pressure, Pump to Rail Part Number: 1170-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

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

1A Pipe - Fuel, High Pressure, Pump to Rail 1170-N0101-01 1 Assembly Tube Nuts and Flare Tube Ends T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 225 1 1 2 0.000 $0.00 $35.51 $15.00 $30.00 $0.00 $0.16 $0.13 $0.29 0.00% 0

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube Stock HP pump to rail 1170-N0101-01-01 1 CNC Tube Bending T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Tube Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC 171 0.25 1 1 0.060 $1.65 $42.18 $100.12 $100.12 $0.10 $0.06 $0.58 $0.74 0.00% 02A Tube Nut HP pump to rail 1170-N0101-01-02 2 Screw Machine Hex Bar Stock T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Tube CNC Operator CNC Turning, LC 288 0.5 2 1 0.088 $1.65 $35.70 $25.00 $50.00 $0.15 $0.06 $0.17 $0.38 0.00% 0

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

0 

0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $0.39 $0.34 $1.06 $1.80 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6

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

Base Cost Impact to Vehicle: $0.39 $0.34 $1.06 $1.80 $0.01 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.008 $16,117 0.00% 2,250,000 60 5.00% $2,020 

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

O

Pa

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

Packaging Cost Total: $0.008

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: Packaging Type: Option #3 PackagingPart Size:=(1/2*(170*70))*50)= 2.975E5mm^3Tote Volume= 508x300x300=45.7E6mm^3Parts/Tote = 150

"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.

Full Quote Modification Differential Quote (Quote Summary includes 

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 7 of 12
Fuel Rail 1101 - GEMA Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: B0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hp Annual Component Volume: 

Component Description: Fuel Rail Assembly Part Number: 1101-B0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

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

1A Fuel Rail Assembly 1101-B0101-01 1 Flow Drill Injector Cups to Rail T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, HC, Base 157 2 1 1 0.000 $0.00 $35.51 $45.00 $45.00 $0.00 $0.45 $0.29 $0.74 0.00% 02A Fuel Rail Assembly 1101-B0101-01 1 Projection Weld Brackets T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 257 1 1 1 0.000 $0.00 $35.51 $15.00 $15.00 $0.00 $0.14 $0.06 $0.20 0.00% 03A Fuel Rail Assembly 1101-B0101-01 1 Assembly end caps and inlet tube and braze weld assembly. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 157 2 1 4 0.000 $0.00 $35.51 $15.00 $60.00 $0.00 $0.45 $0.38 $0.84 0.00% 0

0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube Injector Rail 1101-B0101-01-3 1 Cut to length and back extrude inlet T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Tube Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 300 1 1 1 0.563 $1.65 $42.18 $100.10 $100.10 $0.93 $0.14 $0.33 $1.40 0.00% 02A End Cap 1101-B0101-01-4 2 Stamp T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 706 0.5 1 1 0.011 $1.64 $42.18 $100.10 $100.10 $0.02 $0.03 $0.14 $0.19 0.00% 03A Cup Injector Port 1101-B0101-01-5 4 Stamp T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 735 0.5 1 1 0.006 $1.64 $42.18 $100.10 $100.10 $0.01 $0.03 $0.14 $0.17 0.00% 04A Bracket Rail Mounting 1101-B0101-01-6 2 Stamp T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 679 0.5 1 1 0.095 $1.64 $42.18 $100.10 $100.10 $0.16 $0.03 $0.15 $0.33 0.00% 05A Inlet Tube 1101-B0101-01-7 1 Bend & Form T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Tube Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC 600 0.5 1 1 0.029 $1.65 $42.18 $100.12 $100.12 $0.05 $0.04 $0.17 $0.25 0.00% 0

0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 

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

0 

0 0 0 0 0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $1.36 $1.46 $2.35 $5.18 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.02 

Base Cost Impact to Vehicle: $1.36 $1.46 $2.35 $5.18 $0.02 

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

"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.

Full Quote Modification Differential Quote (Quote Summary includes 

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 8 of 12
Fuel Rail 1101 - GEMA Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: B0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hp Annual Component Volume: 

Component Description: Fuel Rail Assembly Part Number: 1101-B0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

Full Quote Modification Differential Quote (Quote Summary includes 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.069 $138,963 0.00% 2,250,000 60 5.00% $4,180 

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

O

Pa

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

Packaging Cost Total: $0.069

 PACKAGING CALCULATIONS: Packaging Type: Option #3Part Size: Parts/Layer: 1X12Number of Layers 3

Pallet OptionsOption1: 48"(122cm)x45"(114cm)x34"(86cm)Investment $200 US funds (Mike S.)Assume Plastic Returnables Last 5 YearsOption2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)Investment $20K for toolPiece Price, Pallet Base $100/BasePiece Price, Tier Pad $40/PadOption3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)Package: 8 Layers of 6 on single Pallet Base.Cost per Tote: $75/ToteCost per Base $100/BaseCardboard 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, $5.00Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 9 of 12
Injector-1104-GEMA Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hp Annual Component Volume: 

Component Description: Fuel Injector Assembly - Low Pressure, 4 Hole Part Number: 1104-B0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

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

1A Injector Tip Assembly 1104-B0101-01-80 1 Assemble Injector Tip T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly

Mech Assembly, MC, Base

1800 0.5 1 4 0.000 $0.00 $35.51 $30.00 $120.00 $0.00 $0.01 $0.07 $0.08 0.00% 0

2A Injector Needle Assembly 1104-B0101-01-70 1 Assemble Injector Needle T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 480 0.5 2 3 0.000 $0.00 $35.51 $30.00 $180.00 $0.00 $0.04 $0.38 $0.41 0.00% 03A Needle Body Assembly 1104-B0101-01-71 1 Assemble Injector Needle T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly

Mech Assembly, MC, Base

480 2 2 7 0.000 $0.00 $35.51 $30.00 $420.00 $0.00 $0.15 $0.88 $1.02 0.00% 0

4A Solenoid Body Overmold 1104-B0101-01-72 1 Overmold Solenoid Body T1 Assembly, Mark-up Applied @ Bottom. Nylon66-40FMR, Inject. Electromechanical Assembly Mech Assembly, HC, Base 450 2 2 1 0.030 $1.54 $37.35 $45.00 $90.00 $0.05 $0.17 $0.20 $0.41 0.00% 05A Final Assembly 1104-B0101-01-73 1 Final Assembly & Test T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, HC, Base 480 2 2 6 0.000 $0.00 $35.51 $45.00 $540.00 $0.00 $0.15 $1.13 $1.27 0.00% 0

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube Inlet 1104-B010101-01-21 1 Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNC Operator CNC Turning, LC 471 2 5.5 1 0.035 $0.78 $35.70 $25.00 $137.50 $0.03 $0.15 $0.29 $0.47 0.50% 62A Inlet Sleeve Adaptor Stamped 1104-B0101-01-50 1 Stamped T2/T3 Stamp/Form, SSLC A-Steel-41XXS, Bar Cut/Punch/Forming Operator Stamp/Form, SMS, MHC 1200 0.5 1 1 0.008 $0.78 $42.18 $125.10 $125.10 $0.01 $0.02 $0.10 $0.13 0.30% 63A Coupler Fuel Inlet 1104-B0101-01-28 1 Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNC Operator S-CNC Turning, LC 450 1 4 1 0.023 $0.78 $35.70 $35.00 $140.00 $0.02 $0.08 $0.31 $0.41 0.50% 64A Body, Needle 1104-B0101-01-09 1 Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNC Operator S-CNC Turning, LC 465 1 4 1 0.049 $0.78 $35.70 $35.00 $140.00 $0.04 $0.08 $0.30 $0.42 0.50% 65A Can Solenoid Housing 1104-B0101-01-51 1 Stamped T2/T3 Stamp/Form, SSLC A-Steel-41XXS, Bar Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 720 0.5 1 1 0.043 $0.78 $42.18 $100.10 $100.10 $0.03 $0.03 $0.14 $0.20 0.30% 66A Needle Valve 1104-B0101-01-24 1 Stamped/Forged T2/T3 Stamp/Form, SSLC A-Steel-41XXS, Bar Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 600 0.5 1 1 0.005 $0.78 $42.18 $100.10 $100.10 $0.00 $0.04 $0.17 $0.21 0.30% 67A Needle Valve Seat 1104-B0101-01-52 1 Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNC Operator S-CNC Turning, LC 643 0.5 2.5 1 0.005 $0.78 $35.70 $35.00 $87.50 $0.00 $0.03 $0.14 $0.17 0.50% 68A Bracket Injector Hold down 1104-B0101-01-02-01 1 Stamp T2/T3 Stamp/Form, SSLC SPR-Steel, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 1800 0.25 1 1 0.021 $0.65 $42.18 $100.10 $100.10 $0.01 $0.01 $0.06 $0.07 0.30% 68B Bracket Injector Hold down 1104-B0101-01-02 1 Heat Treat & Plate T2/T3 Heat Treat, SSLC General Underhood Plating Plating/Coating Operator Plate/Finish, SMS, LMC 1800 0.5 1 1 0.001 $15.00 $55.17 $100.17 $100.17 $0.02 $0.02 $0.06 $0.09 0.30% 69A Injector Tip Housing 1104-N0101-01-08 1 Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNC Operator S-CNC Turning, MC 450 1 4.5 1 0.003 $0.78 $35.70 $55.00 $247.50 $0.00 $0.08 $0.55 $0.63 0.50% 6

10A Plate - Injector Tip 1104-N0101-01-08-02 1 Stamp T2/T3 CNC Turning, MSMC HC-Steel-4130, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 3600 0.25 1 1 0.000 $0.78 $42.18 $100.10 $100.10 $0.00 $0.00 $0.03 $0.03 0.50% 610B Plate - Injector Tip 1104-N0101-01-08-01 1 Laser Injector Holes T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Milling, LMC 3600 0.25 1 1 0.000 $0.00 $35.70 $125.15 $125.15 $0.00 $0.00 $0.03 $0.04 0.50% 611A Tip Relief Plate 1104-B0101-01-70 1 Stamp T2/T3 Stamp/Form, SSLC HC-Steel-4130, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 2057 0.25 1 1 0.000 $0.78 $42.18 $100.10 $100.10 $0.00 $0.01 $0.05 $0.05 0.30% 6

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

1A Sleeve Screen-Screen Stop 1104-B0101-01-25 1 S 

2A Screen, Fuel Inlet 1104-B0101-01-06 1 S 3A Retainer Metering valve, Upper Spring Seat 1104-B0101-01-17 1 S 4A Ball Needle Seat 1104-B0101-01-23 1 (Used Pricing from Mini Injector) S 5A Spring - Needle Return 1104-B0101-01-12 1 S 6A Solenoid Winding Assembly 1104-N0101-01-22 1 S 7A O-Ring Injector to Rail Seal 1104-B0101-01-61 1 S 8A O-Ring Injector to Head 1104-B0101-01-62 1 S 9A Sleeve Injector Head 1104-B0101-01-63 1 S 

10A Injector Slip Washer 1104-B0101-01-64 1 S 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $1.03 $1.04 $4.86 $6.93 $0.01 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.05 

Base Cost Impact to Vehicle: $1.03 $1.04 $4.86 $6.93 $0.06 

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

38,298

1047

450,000

4

1,800,000

"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.

Full Quote Modification Differential Quote (Quote Summary includes 

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 10 of 12
Injector-1104-GEMA Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hp Annual Component Volume: 

Component Description: Fuel Injector Assembly - Low Pressure, 4 Hole Part Number: 1104-B0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

38,298

1047

450,000

4

1,800,000

Full Quote Modification Differential Quote (Quote Summary includes 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.012 $97,961 0.00% 9,000,000 60 5.00% $4,420 

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

O

Pa

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

Packaging Cost Total: $0.012

 PACKAGING CALCULATIONS: Packaging Type: Option #3 TotePart Size: 90x55x25 mmParts/Layer: 3 x 8Number of Layers: 9

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 11 of 12
Engine Assembly-1100 R5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: OEM Assembly of Fuel Induction Components to Engine Part Number: 1100 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

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

1A Fuel Rail - High Pressure 1101-N0101-02 1

Install Fuel Rail to Cylinder Head (Two Additional Fasteners Over Base GEMA Engine)

OEM Assembly, Mark-up 

Applied @ Bottom. Not Applicable General Assembly-OEM Engine Assembly, OEM 257 1 1 1 0.000 $0.00 $83.31 $150.21 $150.21 $0.00 $0.32 $0.58 $0.91 0.00% 0

2A Fuel Injector Assembly - Solenoid, 7 Hole 1104-N0101-01 4

Install Fuel Injectors to Cylinder Head, Considered Wash to Base Engine

OEM Assembly, Mark-up 

Applied @ Bottom. Not Applicable Not Applicable Not Applicable 451 1 1 1 0.000 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 0.00% 0

Fuel Pump - High Pressure w. Vol.Control Valve (Driven-Off Intake Cam) 1107-N0101-01 1 Install Fuel Pump to Cylinder Head, 3 Fasteners OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Engine Assembly, OEM 171 1 1 1 0.000 $0.00 $83.31 $150.21 $150.21 $0.00 $0.49 $0.88 $1.36 0.00% 0Pipe Assembly - Fuel, High Pressure, Pump to Rail 1170-N0101-01 1

Install High Pressure Pipe Between Fuel Rail and Pump. Run Down Two Tube Nuts

OEM Assembly, Mark-up 

Applied @ Bottom. Not Applicable General Assembly-OEM Engine Assembly, OEM 257 1 1 1 0.000 $0.00 $83.31 $150.21 $150.21 $0.00 $0.32 $0.58 $0.91 0.00% 0

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

1A Fuel Rail - High Pressure (w. HP Sensor) 1101-N0101-02 1 (Mini Cooper) SAC 

2A Fuel Injector Assembly - Solenoid, 7 Hole 1104-N0101-01 4 (Mini Cooper) SAC 3A Fuel Pump - High Pressure w. Vol.Control Valve (Driven-Off Intake Cam) 1107-N0101-01 1 (Mini Cooper) SAC 4A Pipe Assembly - Fuel, High Pressure, Pump to Rail 1170-N0101-01 1 (Mini Cooper) SAC 

0 

5A Fuel Rail Assembly 1101-B0101-01 1 Chrysler GEMA SAC 6A Fuel Injector Assembly - Low Pressure, 4 Hole 1104-B0101-01 4 Chrysler GEMA SAC 

0 

7A Bolt - Fuel Pump (to head) 1180-N0101-02 3 S 8A Bolt - Fuel Rail (to head) 1180-N0101-01 2 S 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $104.14 $1.13 $2.04 $107.31 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

(SAC) &T1 or OEM Mark-Up Values: (103.99) ----- ----- ----- $0.00 

Base Cost Impact to Vehicle: $0.15 $1.13 $2.04 $3.33 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: No Packaging Considerations Required.Packaging Type:Part Size:Parts/Layer:Number of Layers:

"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.

Full Quote Modification Differential Quote (Quote Summary includes 

File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-11, 12 of 12
Appendix G.1 - Subsystem 12

Exhaust Subsystem

 Case Study #0101

MAQS Worksheets

File:Exhaust Subsystem 12 033009.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-12, 1 of 6
Manifold Exhaust 1201 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Manifold - Exhaust, Dual Wall Part Number: 1201-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

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

1A Manifold - Exhaust, Dual Wall (Mini) 1201-N0101-01-02 1 Cast T1 Assembly, Mark-up Applied @ Bottom. NiResist Iron, D5S, Cast Mold/Cast/Sinter Operator Sand Cast, HMC 141 6 1.5 2 7.760 $3.50 $43.52 $150.07 $450.21 $27.16 $1.85 $3.19 $32.20 10.00% 1B Manifold - Exhaust, Dual Wall (Mini) 1201-N0101-01-01 1 Heat Treat, Pre Machine T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Heat Treat Operator Heat Treat, MLS, MHC 129 1 3 1 0.000 $0.00 $46.52 $250.00 $750.00 $0.00 $0.36 $5.83 $6.20 0.00% 

1C Manifold - Exhaust, Dual Wall (Mini) 1201-N0101-01 1 Machining T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Mold/Cast/Sinter Operator CNC Machining, MHC 120 3 3 1.5 0.000 $0.00 $43.52 $45.00 $202.50 $0.00 $1.09 $1.69 $2.78 0.00% 

2A Manifold - Exhaust, (Chrysler) 1201-B0101-01-02 1 Cast T1 Assembly, Mark-up Applied @ Bottom. Nodular Iron, Cast Mold/Cast/Sinter Operator Sand Cast, HMC -145 6 1.5 1 -12.920 $0.35 $43.52 $150.07 $225.11 -$4.52 -$1.81 -$1.56 -$7.89 5.00% 2B Manifold - Exhaust, Dual Wall (Chrysler) 1201-B0101-01-01 1 Heat Treat, Pre Machine T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Heat Treat Operator Heat Treat, MLS, MHC -125 1 2.5 1 0.000 $0.00 $46.52 $250.00 $625.00 $0.00 -$0.37 -$5.00 -$5.37 0.00% 

2C Manifold - Exhaust, Dual Wall (Chrysler) 1201-B0101-01 1 Machining T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Mold/Cast/Sinter Operator CNC Machining, MHC -120 3 3 1 0.000 $0.00 $43.52 $45.00 $135.00 $0.00 -$1.09 -$1.13 -$2.21 0.00% 

0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 

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

0 

0 0 0 0 0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap 

T1 or OEM Total Manufacturing Cost: $22.64 $0.03 $3.03 $25.70 $2.83 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.14 

Base Cost Impact to Vehicle: $22.64 $0.03 $3.03 $25.70 $2.97 

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

"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.

Full Quote Modification Differential Quote (Quote Summary includes 

Casting & Machining Assumptions:Casting: Assumption processing time increase due to part complexity and material grade is offset by reduction in material volume. Machining: 50% premium paid on machining NiResist material over base nodular cast iron. 

File:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-12, 2 of 6
Manifold Exhaust 1201 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Manifold - Exhaust, Dual Wall Part Number: 1201-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

Full Quote Modification Differential Quote (Quote Summary includes 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Rack/Pallet Investment Amortization: $0.152 $303,191 0.00% 2,250,000 60 5.00% $380 

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

P

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

Packaging Cost Total: $0.152

 PACKAGING CALCULATIONS: MINI Packaging Type: Option #2Part Size:320x120X115Parts/Layer: 3x10Number of Layers: 7Cost $0.03/Part

 PACKAGING CALCULATIONS: GEMA Packaging Type: Option #2Part Size: 380x280x130Parts/Layer:3x4Number of Layers: 6Cost = $0.076/Part

File:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-12, 3 of 6
Exh. Brkt's-Heat Shields 1275 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Bracket Subassembly- Heat Shield, Top, Turbo Part Number: 1275-N0101-02 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

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

Bracket Subassembly- Heat Shield, Top, Turbo 1275-N0101-02 1 Install Ceramic Fiber Paper (Fiberfrax 440), crimp and form. T1 Assembly, Mark-up Applied @ Bottom. Fiberfrax 440 General Assembly Mech Assembly, MC, Base 450 1 1 1 256 $0.01 $35.51 $30.00 $30.00 $1.77 $0.08 $0.07 $1.91 0.00% 

0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 

Material Labor Burden TMC Scrap 

T1 or OEM Total Manufacturing Cost: $1.77 $0.08 $0.07 $1.91 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 

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

Base Cost Impact to Vehicle: $1.77 $0.08 $0.07 $1.91 $0.01 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 

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

P

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

Packaging Cost Total: $0.000

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

 PACKAGING CALCULATIONS: Packaging Type:Part Size:Parts/Layer:Number of Layers:

Full Quote Modification Differential Quote (Quote Summary includes 

Material Size "In^2" and Material Cost $/Inch^2.

File:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-12, 4 of 6
Exhaust Sealing 1285 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Bracket Subassembly - Exhaust Manifold w. Integrated Gasket Part Number: 1275-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

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

1A Bracket Subassembly - Exhaust Manifold w. Integrated Gasket 1275-N0101-01 1

Upgrade from 2 to 3 layer exhaust gasket. Only considering gasket, no consideration required for heat shield mounting.

S 

0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $0.95 $0.00 $0.00 $0.95 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

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

Base Cost Impact to Vehicle: $0.95 $0.00 $0.00 $0.95 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

 PACKAGING CALCULATIONS: Packaging Type:Part Size:Parts/Layer:Number of Layers:

"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.

Full Quote Modification Differential Quote (Quote Summary includes 

File:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-12, 5 of 6
Engine Assembly 1200 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Vehicle Operations or Engine Assembly of Exhaust Components Part Number: 1200 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

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

0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 

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

Manifold Exhaust 1201-N0101-01 1 SAC 

Exhaust Brackets/Heat Shields 1275-N0101-02 1 SAC Exhaust Sealing 1275(85)-N0101-01 1 SAC Nut- Manifold Exhaust to Cylinder Head 1280-N0101-01 10 S Nut - Turbo to C.C. Catalytic Converter 1280-N0101-06 3 S Nut - Exhaust Manifold to Turbo 1280-N0101-07 4 (0.193-0.05) S 

0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $37.77 $0.00 $0.00 $37.77 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

(SAC) &T1 or OEM Mark-Up Values: (35.88) ----- ----- ----- $0.00 

Base Cost Impact to Vehicle: $1.89 $0.00 $0.00 $1.89 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

 PACKAGING CALCULATIONS: Packaging Type: No change to packaging Part Size:Parts/Layer:Number of Layers:

"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.

Full Quote Modification Differential Quote (Quote Summary includes 

Cover cost of Nut-Exhaust Manifold to Turbo in Air Induction Engine Assembly Cost Sheet.

No differential labor/burden costs incurred to assembly exhaust system components. 

File:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-12, 6 of 6
Appendix G.1 - Subsystem 13

Lubrication Subsystem

 Case Study #0101

MAQS Worksheets

File:13 Lubrication Subsystem 032309.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-13, 1 of 11
Oil Pump 1302 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Oil Pump Assembly Part Number: 1302-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

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

1A Oil Pump Assembly 1302-N0101-01 1 Increase in Pump Capacity 15- 20% (13%PCJ & 5% Turbo) S 

0 0 0 0 0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $3.08 $0.00 $0.00 $3.08 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.02 

Base Cost Impact to Vehicle: $3.08 $0.00 $0.00 $3.08 $0.02 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: No Packaging Updates RequiredPackaging Type:Part Size:Parts/Layer:Number of Layers:

"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.

Full Quote Modification Differential Quote (Quote Summary includes 

File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 2 of 11
Filter Cooler Assembly 1306 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Filter Cooler Assembly - Oil (Includes Seals) Part Number: 1306-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

1A Oil Cooler Adapter/Base Plate Subassembly 1306-N0101-01-02-1A 1 Toggle Lock Adaptor and Base Plate Together S Not Applicable General Assembly Mech. Assembly, MC 300 1 0.000 $0.00 $35.51 $125.19 $0.00 $0.12 $0.42 $0.54 0.00% 0.00% 0.00% 0.00% 02A Oil Cooler 1306-N0101-01-02 1 Fixture and Braze Weld S Not Applicable General Assembly Mech. Assembly, MC 180 1 0.000 $0.00 $35.51 $125.19 $0.00 $0.20 $0.70 $0.89 0.00% 0.00% 0.00% 0.00% 03A Filter Cooler Assembly - Oil (Includes Seals & 

aux

1306-N0101-01 1

Final Assembly of filter/cooler assembly (Only Consider Turbo/DI Driven Costs)

S Not Applicable General Assembly Mech. Assembly, MC 240 5 0.000 $0.00 $35.51 $125.19 $0.00 $0.74 $0.52 $1.26 0.00% 0.00% 0.00% 0.00% 0

Purchase Part - High Impact Item (Full Cost Mapping)

1A Housing Oil Filter Preassembled 1306-N0101-01-08 1 Casting (50% Mass Attributed to Turbo/DI oil cooler features) S Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC 160 1 0.900 $1.10 $43.52 $100.05 $0.99 $0.27 $0.63 $1.89 0.30% 6.00% 4.00% 0.00% 101B Housing Oil Filter Preassembled 1306-N0101-01-08 1

Machine Casting Features (Hole Attributed to Turbo/DI Only)

S Not Applicable Mold/Cast/Sinter Operator Perm. Cast, MHC 150 1 0.000 $0.00 $43.52 $150.06 $0.00 $0.29 $1.00 $1.29 0.30% 6.00% 4.00% 0.00% 10

2A Oil Cooler Adapter Plate 1306-N0101-01-02-1 1 Stamping S Aluminum-3003/4047B, Cladding Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 480 0.5 0.253 $2.10 $42.18 $100.10 $0.53 $0.04 $0.21 $0.78 0.30% 6.00% 4.00% 0.00% 103A Oil Cooler Base Plate 1306-N0101-01-02-2 1 Stamping S Aluminum-3003/4047B, Cladding Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 480 0.5 0.253 $2.10 $42.18 $100.10 $0.53 $0.04 $0.21 $0.78 0.30% 6.00% 4.00% 0.00% 104A Oil Cooler Cooling Plate stack-Lance 1306-N0101-01-02-3 5 Stamping S Aluminum-3003/4047A, Cladding Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 581 1 0.018 $1.65 $42.18 $100.10 $0.03 $0.07 $0.17 $0.27 0.30% 6.00% 4.00% 0.00% 105A Oil Cooler Cooling Plate stack 1306-N0101-01-02-31 7 Stamping S Aluminum-3003/4047A, Cladding Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 1161 0.5 0.018 $1.65 $42.18 $100.10 $0.03 $0.02 $0.09 $0.13 0.30% 6.00% 4.00% 0.00% 106A Oil Cooler Top Plate 1306-N0101-01-02-4 1 Stamping S Aluminum-3003/4047A, Cladding Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 581 0.5 0.062 $1.65 $42.18 $100.10 $0.10 $0.04 $0.17 $0.31 0.30% 6.00% 4.00% 0.00% 10

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

Su

Ac

1A Gasket housing to block Oil 1306-N0101-01-09 1 S $2A Gasket housing to block - coolant 1306-N0101-01-10 1 S $3A Gasket Oil Cooler Odd Shape 1306-N0101-01-07 1 S $4A Gasket Oil Cooler Square 1306-N0101-01-06 1 S $5A Gasket Oil Cooler Oval 1306-N0101-01-05 1 S $6A Gasket Oil Cooler Round 1306-N0101-01-04 1 S $7A Bolt Oil Cooler to housing 1306-N0101-01-03 5 S $8A Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to Turbocharger 1370-N0101-01 1 SAC $

0 $0 $0 $0 $0 $0 $0 $0 $0 $

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 3 of 11
Filter Cooler Assembly 1306 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Filter Cooler Assembly - Oil (Includes Seals) Part Number: 1306-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote Modification Quote X Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

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

Ma

T1 or OEM Total Manufacturing Cost: $7.02 $2.23 $5.31 $14.57 $0.02 $0.44 $0.29 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15

(SAC) &T1 or OEM Mark-Up Values: (4.09) ----- ----- ----- $0.08 $1.00 $0.92 $0.38 $

Base Cost Impact to Vehicle: $2.93 $2.23 $5.31 $10.48 $0.10 $1.44 $1.21 $0.38 $

Packaging Calculations 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

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.068 $136,778 0.00% 2,250,000 60 5.00% $200 684 84 

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

O

Pal

Expendable Packaging in Piece Cost: $0.10 $1.00 8 $0.00 0 $0.00 0 $0.00 0 $0.00 

Packaging Cost Total: $0.164

File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 4 of 11
Tube Ass'y Turbo to Block 1370 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Tube Assembly - Oil, Turbo to Engine Block Part Number: 1370 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

Tube Assembly - Oil, Turbo to Engine Block 1370-N0101-02 1

Assemble End Fittings and Orings onto Tube and Crimp in Place. Pressure Test

S Not Applicable General Assembly Mech. Assembly, LC 240 2 0.000 $0.00 $35.51 $100.19 $0.00 $0.30 $0.42 $0.71 0.00% 0.00% 0.00% 0.00% 0

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube Stock - Oil, Turbo to Engine Block 1370-N0101-02-2 1 Tube Bending S LC-Steel-1215, Tubing Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC360 0.5 0.210 $0.62 $42.18 $100.12 $0.13 $0.06 $0.28 $0.47 0.00% 0.00% 0.00% 0.00% 01B Tube Stock - Oil, Turbo to Engine Block 1370-N0101-02-1 1 Flare Tube Ends S Not Applicable Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC240 1 0.210 $0.00 $42.18 $100.12 $0.00 $0.18 $0.42 $0.59 0.00% 0.00% 0.00% 0.00% 0

1C Tube Stock - Oil, Turbo to Engine Block 1370-N0101-02-3 1 Plate S General Underhood PlatingPlating/Coating Operator Plate/Finish, SMS, MHC 720 1 0.001 $15.00 $55.17 $125.17 $0.02 $0.08 $0.17 $0.27 0.30% 6.00% 4.00% 0.00% 10

2A Fitting Tube End 1370-N0101-02-4 2 Forge Blank S MC-Steel-1018, Bar Forging Operator Cold Forge, LMC 900 0.5 0.165 $0.55 $38.52 $100.09 $0.09 $0.02 $0.11 $0.22 0.00% 0.00% 0.00% 0.00% 02B Fitting Tube End 1370-N0101-02-4 2 Machine S Not Applicable CNC Operator CNC Milling, SMS, LC 360 0.5 0.000 $0.00 $35.70 $100.15 $0.00 $0.05 $0.28 $0.33 0.00% 0.00% 0.00% 0.00% 0

2C Fitting Tube End 1370-N0101-02-4 2 Plate S General Underhood PlatingPlating/Coating Operator Plate/Finish, SMS, MHC 1800 1 0.001 $15.00 $55.17 $125.17 $0.02 $0.03 $0.07 $0.12 0.30% 6.00% 4.00% 0.00% 10

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

Su

Ac

1A O-ring - Tube Fitting 1370-N0101-02-3 1 S $

0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $

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

Ma

T1 or OEM Total Manufacturing Cost: $0.42 $0.81 $2.20 $3.43 $0.00 $0.03 $0.02 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 0.00% 10

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.21 $0.14 $0.00 $

Base Cost Impact to Vehicle: $0.42 $0.81 $2.20 $3.43 $0.01 $0.24 $0.16 $0.00 $

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 5 of 11
Tube Ass'y Turbo to Block 1370 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Tube Assembly - Oil, Turbo to Engine Block Part Number: 1370 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

Packaging Calculations 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

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.055 $110,206 0.00% 2,250,000 60 5.00% $4,420 25 2304 

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

O

Pal

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

Packaging Cost Total: $0.055

File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 6 of 11
Tube Ass'y Oil Cool-Turbo1370 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to Turbocharger Part Number: 1370-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate 

M

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

1A Fitting Hose Oil Cooler to Turbo 1306-N0101-01-11-2 1 Braze weld Tube Fitting to Bracket Mount S Not Applicable General Assembly Mech. Assembly, LC 257 1 0.000 $0.00 $35.51 $100.19 $0.00 $0.14 $0.39 $0.53 0.00% 0.00% 0.00% 0.00% 1B Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to Turbocharger 1306-N0101-01-11 (1370-N0101-01) 1 Crimp End Fitting to Hose and Add Protective Heat Shield, Oring and Clamp S Not Applicable General Assembly Mech. Assembly, LC 240 3 0.000 $0.00 $35.51 $100.19 $0.00 $0.44 $0.42 $0.86 0.00% 0.00% 0.00% 0.00% 

Purchase Part - High Impact Item (Full Cost Mapping)

1A Hose Oil Cooler to Turbo 1306-N0101-01-11-1 1 Extrude & Shape Hose S

SBR-Fiber Rein. W. Outer Wrap, Extruded

Extruding/Drawing Operator Comp./Ext. Mold, LMC 545 1.5 0.007 $2.05 $54.35 $100.04 $0.01 $0.15 $0.18 $0.35 0.00% 0.00% 0.00% 0.00% 

2A Tube Fitting end 1306-N0101-01-11-2-1 1 Machining S LC-Steel-1215, Tubing CNC Operator CNC Turning, LMC 200 0.25 0.150 $0.62 $35.70 $100.00 $0.09 $0.04 $0.50 $0.64 0.00% 0.00% 0.00% 0.00% 3A Bracket Tube Fitting end attach 1306-N0101-01-11-2-1-1 1 Fine blank, LMC S LC-Steel-1000S, Coil Cut/Punch/Forming Operator Fine blank, LMC 1000 0.5 0.207 $0.45 $42.18 $100.13 $0.09 $0.02 $0.10 $0.21 0.30% 6.00% 4.00% 0.00% 1

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

S

A

1A Collar Tube fitting attachment 1306-N0101-01-11-2-1-2 1 S 2A Heat Shield, Hose 1306-N0101-01-11-2 1 S 3A Hose Clamp 1306-N0101-01-11-3 1 S 4A O-ring 1306-N0101-01-11-4 1 S 

0 0 0 0 0 0 0 0 0 0 

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

T1 or OEM Total Manufacturing Cost: $1.27 $0.80 $1.59 $3.66 $0.00 $0.01 $0.01 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 0.00% 1

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.22 $0.15 $0.00 

Base Cost Impact to Vehicle: $1.27 $0.80 $1.59 $3.66 $0.01 $0.23 $0.16 $0.00 

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 7 of 11
Tube Ass'y Oil Cool-Turbo1370 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to Turbocharger Part Number: 1370-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate 

M

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

Packaging Calculations 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

S

Cu

I

I

Re

Rack/Pallet Investment Amortization: $0.026 $51,950 0.00% 2,250,000 60 5.00% $5,860 9 6480 

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

Oth

P

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

Packaging Cost Total: $0.026

File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 8 of 11
Oil - Synthetic 1399 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Oil - Synthetic Part Number: 1399-N0101-08 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

Su

Ac

1A OIL - ENGINE 0W-40 ILSAC GF3 MS-10725 NA 1 S $

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

Ma

T1 or OEM Total Manufacturing Cost: $4.00 $0.00 $0.00 $4.00 $0.00 $0.00 $0.00 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0

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

Base Cost Impact to Vehicle: $4.00 $0.00 $0.00 $4.00 $0.00 $0.00 $0.00 $0.00 $

Packaging Calculations 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

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 

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

O

Pal

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 9 of 11
Engine Assembly 1300 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: OEM Assembly of Additional or Revised Lubrication Components to Engine Part Number: 1300-N0101-00 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate 

M

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

1A Tube Assembly - Oil, Turbo to Engine Block 1370-N0101-02 1 Install Tube Assembly to Engine OEM Not Applicable General Assembly-OEM Engine Assembly, OEM 129 1 0.000 $0.00 $83.31 $150.21 $0.00 $0.65 $1.17 $1.82 0.00% 0.00% 0.00% 0.00% 2A Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to Turbocharger 1306-N0101-01-11 (1370-N0101-01) 1 Install Hose to Turbo Assembly, Run Down Bolt OEM Not Applicable General Assembly-OEM Engine Assembly, OEM 240 1 0.000 $0.00 $83.31 $150.21 $0.00 $0.35 $0.63 $0.97 0.00% 0.00% 0.00% 0.00% 3A Filter Cooler Assembly - Oil (Includes Seals) 1306-N0101-01 1 Install Filter Cooler Assembly and Run Down 4 Bolts OEM Not Applicable General Assembly-OEM Engine Assembly, OEM 180 1 0.000 $0.00 $83.31 $150.21 $0.00 $0.46 $0.83 $1.30 0.00% 0.00% 0.00% 0.00% 

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

Ac

1A Bolt - Tube Assembly , Oil, Turbo Outlet & Block I 1380-N0101-06 2 Banjo Bolts S 2A Washer - Bolt - Tube Assembly , Oil, Turbo Outlet 1380-N0101-09 4 Banjo Washers S 3A Tube Assembly - Oil, Turbo to Engine Block 1370-N0101-02 1 SAC 4A Bolt hose oil cooler to turbo 1306-N0101-01-12 1 S 5A Bolt - Filter Cooler Assembly 1380-N0101-08 4 S 6A Filter Cooler Assembly - Oil (Includes Seals) 1306-N0101-01 1 SAC 7A Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to Turbocharger 1370-N0101-01 1 SAC 

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

T1 or OEM Total Manufacturing Cost: $22.64 $1.46 $2.63 $26.72 $0.00 $0.00 $0.00 $0.00 

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

(SAC) &T1 or OEM Mark-Up Values: (21.71) ----- ----- ----- $0.00 $0.00 $0.00 $0.00 

Base Cost Impact to Vehicle: $0.93 $1.46 $2.63 $5.02 $0.00 $0.00 $0.00 $0.00 

Packaging Calculations 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

Cu

Re

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 

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

Ot

P

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COST

10

9,574

47

450,000

1

450,000

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 10 of 11
Engine Assembly 1300 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: OEM Assembly of Additional or Revised Lubrication Components to Engine Part Number: 1300-N0101-00 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate 

M

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COST

10

9,574

47

450,000

1

450,000

File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-13, 11 of 11
Appendix G.1 - Subsystem 14

Cooling Subsystem

 Case Study #0101

MAQS Worksheets

File:14 Cooling System 033109.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-14, 1 of 9
Pump-Aux. Coolant 1401 R5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Pump- Auxiliary Coolant, Electric Part Number: 1401-N0101-02 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

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

1A Charge Impeller Assembly 1401-N0101-02-3-1 1 Magnetize Impeller Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 240 1 1 1 0.000 $0.00 $35.51 $30.00 $30.00 $0.00 $0.15 $0.13 $0.27 0.00% 02A Pump-Auxiliary Coolant Final Assembly 1401-N0101-02 1 Final Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 240 2 1 9 0.000 $0.00 $35.51 $30.00 $270.00 $0.00 $0.30 $1.13 $1.42 0.00% 0

INTENTIONAL BLANK SPACE 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 

3A Pump-Auxiliary Coolant, Electric Subassembly 1401- N0101-00 (New P/N ) 1 Assemble pump to bracket and hoses to pump. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 200 4 1 4 0.000 $0.00 $35.51 $15.00 $60.00 $0.00 $0.71 $0.30 $1.01 0.00% 0

0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 

Purchase Part - High Impact Item (Full Cost Mapping)

1A Motor Housing Assembly 1401-N0101-02-1-1 1 Injection Mold Housing w. Terminals T1 Assembly, Mark-up Applied @ Bottom. PPS-GF40, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS 360 0.5 1 2 0.110 $6.02 $43.52 $150.01 $300.02 $0.66 $0.06 $0.83 $1.56 0.00% 02A End Cap Motor close out 1401-N0101-02-1-2 1 Injection Mold Housing w. Terminals T1 Assembly, Mark-up Applied @ Bottom. PPS-GF35-MF30, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS 769 0.5 1 1 0.025 $3.86 $43.52 $150.01 $150.01 $0.10 $0.03 $0.20 $0.32 0.00% 03A Housing Impellor Cavity 1401-N0101-02-2-1 1 Injection Mold Housing w. Terminals T1 Assembly, Mark-up Applied @ Bottom. PPS-GF35-MF30, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS 626 0.5 1 1 0.094 $3.86 $43.52 $150.01 $150.01 $0.36 $0.03 $0.24 $0.64 0.00% 04A Impellor Water Pump 1401-N0101-02-3-1-1 1 Injection Mold Housing w. Terminals T1 Assembly, Mark-up Applied @ Bottom. PPS-GF40, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS 333 0.5 1 1.5 0.100 $6.02 $43.52 $150.01 $225.02 $0.60 $0.07 $0.68 $1.34 0.00% 0

INTENTIONAL BLANK SPACE 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 

1A Bracket Subassembly - Auxiliary Pump to Oil Filter/Cooler Ass'y 1475-N0101-01-03 1 Progressive Die Blank T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 600 0.5 1 1 0.808 $0.45 $42.18 $100.10 $100.10 $0.36 $0.04 $0.17 $0.57 0.00% 01B Bracket Subassembly - Auxiliary Pump to Oil Filter/Cooler Ass'y 1475-N0101-01-02 1 Stage Tooling (3 Stage) T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 240 1 1 1 0.000 $0.00 $42.18 $100.10 $100.10 $0.00 $0.18 $0.42 $0.59 0.00% 0

1C Bracket Subassembly - Auxiliary Pump to Oil Filter/Cooler Ass'y 1475-N0101-01-01 1 Apply Coating T2/T3 Plate/Finish Mech., SSLC Powder Coat Plating/Coating Operator Plate/Finish, SMS, LMC 720 1 1 1 0.010 $20.00 $55.17 $100.17 $100.17 $0.20 $0.08 $0.14 $0.42 0.30% 6

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

1A Terminals 1401-N0101-02-71 1 Terminals Tin Plate S 

2A O-ring - Motor Housing to Impeller Housing 1401-N0101-02-72 1 Silicone S 3A AlNiCo Magnets 1401-N0101-02-73 4 (Uncharged, Approx 10x20x2.5) S 4A Motor Winding Assembly 1401-N0101-02-1-1-3 1 S 5A PCB Motor Control Assembly 1401-N0101-02-1-1-2 1 S 6A E-Clip 1401-N0101-02-5 1 S 7A Heat Sink 1401-N0101-02-6 1 S 8A Screw Impellor cavity to motor housing 1401-N0101-02-2-2 4 S 9A Bolt pump to bracket 1401-N0101-02-02 3 S 

10A Wire Harness Retention Clips NA 2 Required for O2 Sensor, Thus No Cost Impact. S 11A Hose Assembly - Oil Filer/Cooler Ass'y to Auxiliary Pump 1470-N0101-04 1 SAC 12A Hose Assembly - Auxiliary Pump to Turbo 1470-N0101-03 1 SAC 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $19.78 $1.63 $4.22 $25.63 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7

(SAC) &T1 or OEM Mark-Up Values: (5.88) ----- ----- ----- $0.18 

Base Cost Impact to Vehicle: $13.90 $1.63 $4.22 $19.75 $0.18 

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

"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.

Full Quote Modification Differential Quote (Quote Summary includes 

File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-14, 2 of 9
Pump-Aux. Coolant 1401 R5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Pump- Auxiliary Coolant, Electric Part Number: 1401-N0101-02 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

Full Quote Modification Differential Quote (Quote Summary includes 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.059 $118,203 0.00% 2,250,000 60 5.00% $500 

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

O

Pa

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

Packaging Cost Total: $0.059

 PACKAGING CALCULATIONS: Packaging Type: Option 1 w. Expendable DividersPart Size: 340X130X90Parts/Layer:3X9Number of Layers: 9

File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-14, 3 of 9
Hose,Oil Cool. - Aux Pump 1470D Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Locati

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Locati

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Meth

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specificati

Component Description: Hose Assembly - Oil Filer/Cooler Ass'y to Auxiliary Pump Part Number: 1470-N0101-04 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 2 * Qty per Ass'y

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

1A Hose - Oil Filter/Cooler Ass'y to Auxiliary Pump 1470-N0101-04-1 1 Extrude & Shape Hose S SBR-Fiber Rein., Extruded Extruding/Drawing Operator Comp./Ext. Mold, LMC 273 1.5 0.127 $1.85 $54.35 $100.04 $0.23 $0.30 $0.37 $0.90 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.90 $0.2A Hose - Oil Filter/Cooler Ass'y to Auxiliary Pump 1470-N0101-04-1 1 Assemble Sheathing and Glue Clamps S Purchased Parts General Assembly Mech Assembly, LC, Base 240 2 $0.62 $1.00 $35.51 $15.00 $0.62 $0.30 $0.06 $0.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.98 $0.

0 ##### 0 0.000 #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.

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, 

PIA

Purch

Price 

End I

1A Sheath Hose Protection (Aux-Filter) 1470-N0101-04-2 1 Nylon B2B $0.00 $0.28 $0.28 $0.

2A Hose Clamp 1470-N0101-03-1 2 Steel- Zinc Phosphate B2B $0.00 $0.17 $0.34 $0.

0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.0 $0.00 $0.00 $0.00 $0.

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Mark-up $1.

T1 or OEM Total Manufacturing Cost: $0.85 $0.59 $0.43 $1.88 $0.00 $0.00 $0.00 $0.00 $0.00 $1.

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 0.00% 10.30%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.11 $0.08 $0.00 $0.19

Base Cost Impact to Vehicle: $0.85 $0.59 $0.43 $1.88 $0.01 $0.11 $0.08 $0.00 $0.19 $2.

Packaging Cost: $0.

Net Cost Impact to Vehicle: $2.

Packaging Calculations 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 

Requiremen

ts (Weeks)

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 57447 1 6 57447

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

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS TOTAL COST

10

9,574

47

450,000

1

450,000

Packaging Pump, No 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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

1

File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-14, 4 of 9
Hose Ass'y-Turbo-Aux Pump 1470C Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Hose Assembly - Auxiliary Pump to Turbo Part Number: 1470-N0101-03 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

1A Fitting Hose End 1306-N0101-01-11-5 1 Cold Headed Tubing S LC-Steel-1215, Tubing Forging Operator Cold Forge, LMC 720 0.5 0.092 $0.62 $38.52 $100.09 $0.06 $0.03 $0.14 $0.22 0.00% 0.00% 0.00% 0.00% 02A Fitting Tube End 1370-N0101-02-4 1 CNC Machine S LC-Steel-1215, Bar CNC Operator CNC Turning, MHC 240 0.5 0.270 $0.62 $35.70 $125.00 $0.17 $0.07 $0.52 $0.76 0.00% 0.00% 0.00% 0.00% 03A Tube 1306-N0101-01-11-5-2 1 Cut to size and form S LC-Steel-1215, Tubing Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC 360 0.5 0.030 $0.62 $42.18 $100.12 $0.02 $0.06 $0.28 $0.36 0.00% 0.00% 0.00% 0.00% 04A Tube Assembly - Banjo Joint for Turbo 1470-N0101-03-03 1 Assemble, Braze and Plate S Not Applicable General Assembly Mech. Assembly, LC 257 2 0.000 $0.00 $35.51 $100.19 $0.00 $0.28 $0.39 $0.67 0.00% 0.00% 0.00% 0.00% 05A Hose Assembly - Auxiliary Pump to Turbo 1470-N0101-03-02 1 Extrude & Shape Hose S SBR-Fiber Rein., Extruded Extruding/Drawing Operator Comp./Ext. Mold, LMC 581 1.5 0.091 $1.85 $54.35 $100.04 $0.17 $0.14 $0.17 $0.48 0.00% 0.00% 0.00% 0.00% 06A Hose Assembly - Auxiliary Pump to Turbo 1470-N0101-03-01 1 Overmold Banjo Tube to Hose S Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 360 1 0.007 $1.74 $43.52 $100.01 $0.01 $0.12 $0.28 $0.41 0.00% 0.00% 0.00% 0.00% 07A Hose Assembly - Auxiliary Pump to Turbo 1470-N0101-03 1 Assemble Sheathing and Glue Clamp S Purchased Parts General Assembly Mech Assembly, LC, Base 200 1 $0.30 $1.00 $35.51 $15.00 $0.30 $0.18 $0.08 $0.55 0.00% 0.00% 0.00% 0.00% 0

0 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0

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

Su

Ac

1A Hose Clamp 1470-N0101-03-1 1 Steel- Zinc Phosphate B3C $2A Sheath Hose protection (Turbo) 1470-N0101-03-2 1 B3C $

$

0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $

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

Ma

T1 or OEM Total Manufacturing Cost: $0.72 $0.87 $1.85 $3.45 $0.00 $0.00 $0.00 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 0.00% 10

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.21 $0.14 $0.00 $

Base Cost Impact to Vehicle: $0.72 $0.87 $1.85 $3.45 $0.01 $0.21 $0.14 $0.00 $

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-14, 5 of 9
Hose Ass'y-Turbo-Aux Pump 1470C Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Hose Assembly - Auxiliary Pump to Turbo Part Number: 1470-N0101-03 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

Packaging Calculations 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

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 

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

O

Pal

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

Packaging Cost Total: $0.000

File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-14, 6 of 9
Hose Ass'y Turbo-Thermo, 1470 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Hose Assembly - Turbo Assembly to Thermostat/Coolant Valve Part Number: 1470-N0101-02 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate 

M

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

1A Tube Assembly Prefabricated 1470-N0101-02-04-01 1 Assemble, Braze S Not Applicable General Assembly Mech Assembly, HC, Base 240 1 0.000 $0.00 $35.51 $45.00 $0.00 $0.15 $0.19 $0.34 0.00% 0.00% 0.00% 0.00% 2A Tube Assembly Prefabricated 1470-N0101-02-04-02 1 Projection Weld Brkt S Not Applicable General Assembly Mech Assembly, LC, Base 240 1 0.000 $0.00 $35.51 $15.00 $0.00 $0.15 $0.06 $0.21 0.00% 0.00% 0.00% 0.00% 3A Tube Assembly Prefabricated 1470-N0101-02-04-02 1 Plating S General Underhood Plating Plating/Coating Operator Plate/Finish, MLS, LMC 720 1 0.001 $15.00 $55.17 $150.17 $0.02 $0.08 $0.21 $0.30 0.00% 0.00% 0.00% 0.00% 4A Hose Assembly - Turbo Assembly to Thermostat/Coolant Valve 1470-N0101-02 1 Assemble SBR Tube with two hose clamps S Not Applicable General Assembly Mech Assembly, LC, Base 240 2 0.000 $0.00 $35.51 $15.00 $0.00 $0.30 $0.06 $0.36 0.00% 0.00% 0.00% 0.00% 

0 ##### 0 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 

Purchase Part - High Impact Item (Full Cost Mapping)

1A Fitting Tube End 1370-N0101-02-4 1 CNC Machine S LC-Steel-1215, Bar CNC Operator CNC Turning, MHC 240 0.5 0.270 $0.62 $35.70 $125.00 $0.17 $0.07 $0.52 $0.76 0.00% 0.00% 0.00% 0.00% 2A Bracket Tube Attachment 1470-N0101-02-4-4 1 Stamping S LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 600 0.5 0.233 $0.45 $42.18 $100.10 $0.10 $0.04 $0.17 $0.31 0.00% 0.00% 0.00% 0.00% 3A Preformed Tube 10mm OD 1470-N0101-02-4-1 1 Cut to size and form S LC-Steel-1215, Tubing Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC 360 0.5 0.150 $0.62 $42.18 $100.12 $0.09 $0.06 $0.28 $0.43 0.00% 0.00% 0.00% 0.00% 4A Preformed Tube 14mm OD 1470-N0101-02-4-2 1 Cut to size and form S LC-Steel-1215, Tubing Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC 240 1 0.060 $0.62 $42.18 $100.12 $0.04 $0.18 $0.42 $0.63 0.00% 0.00% 0.00% 0.00% 5A Hose - Oil Filter/Cooler Ass'y to Auxiliary Pump 1470-N0101-04-1 1 Extrude & Shape Hose S SBR-Fiber Rein., Extruded Extruding/Drawing Operator Comp./Ext. Mold, LMC 933 1.5 0.055 $1.85 $54.35 $100.04 $0.10 $0.09 $0.11 $0.30 0.00% 0.00% 0.00% 0.00% 

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

S

A

1A Hose Clamp small ID 1470-N0101-02-2 1 S 2A Hose Clamp large ID 1470-N0101-02-3 1 S 

0 0 0 0 0 0 0 0 0 0 0 0 

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

T1 or OEM Total Manufacturing Cost: $1.02 $1.10 $2.01 $4.13 $0.00 $0.00 $0.00 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.03% 6.00% 4.00% 0.00% 1

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.25 $0.17 $0.00 

Base Cost Impact to Vehicle: $1.02 $1.10 $2.01 $4.13 $0.00 $0.25 $0.17 $0.00 

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-14, 7 of 9
Hose Ass'y Turbo-Thermo, 1470 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Hose Assembly - Turbo Assembly to Thermostat/Coolant Valve Part Number: 1470-N0101-02 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate 

M

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

Packaging Calculations 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

S

Cu

I

I

Re

Rack/Pallet Investment Amortization: $0.015 $30,395 0.00% 2,250,000 60 5.00% $200 152 378 

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

Oth

P

Expendable Packaging in Piece Cost: $0.03 $1.00 10 $3.00 0 $0.00 0 $0.00 0 $0.00 

Packaging Cost Total: $0.042

File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-14, 8 of 9
Engine Assembly 1400 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: OEM Assembly of Additional or Revised Assembly Components to Engine Part Number: 1400-N0101-00 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

1A Assembly Pump-Aux. Coolant Subassembly 1401-N0101-02+ Subs 1

Mount Auxiliary Pump to Oil 

Cooler/Filter (2 Screws), Make Electrical Connection Constrain wire in Clips

OEM Not Applicable General Assembly-OEM Engine Assembly, OEM 129 1 0.000 $0.00 $83.31 $150.21 $0.00 $0.65 $1.17 $1.82 0.00% 0.00% 0.00% 0.00% 0

2A Hose Assembly, Turbo -Aux Pump and Hose Ass'y- Turbo - Thermostat Valve 1470-N0101-02/03 1 Install and run Banjo bolt (x2) @ turbo. OEM Not Applicable General Assembly-OEM Engine Assembly, OEM 129 1 0.000 $0.00 $83.31 $150.21 $0.00 $0.65 $1.17 $1.82 0.00% 0.00% 0.00% 0.00% 03A Hose, Oil Cooler to Aux Pump and Hose Ass'y Turbo Thermostat Valve to Thermostat Valve 1470-N0101-02/04 1 Press on Tubes and release Hose Clamps OEM Not Applicable General Assembly-OEM Engine Assembly, OEM 129 1 0.000 $0.00 $83.31 $150.21 $0.00 $0.65 $1.17 $1.82 0.00% 0.00% 0.00% 0.00% 04A Hose Assembly - Turbo Assembly to Thermostat/Coolant Valve 1470-N0101-02 0 Run fastener to secure Hose Assembly Bracket to Engine OEM Not Applicable General Assembly-OEM Engine Assembly, OEM 300 1 0.000 $0.00 $83.31 $150.21 $0.00 $0.28 $0.50 $0.78 0.00% 0.00% 0.00% 0.00% 0

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

Su

Ac

1A Bolt-Hose, coolant Inlet and Outlet @ Turbo 1480-N0101-06 2 Banjo Bolts S $2A Washer banjo Bolt-Hose, coolant Inlet and Outlet @1480-N0101-13 4 Banjo Washers S $3A Bolt-Hose Bracket, coolant Inlet and Outlet @ Turbo 1480-N0101-14 1 S $4A Bolt Aux pump bracket to oil cooler 1480-N0101-07 3 S $5A Pump- Auxiliary Coolant, Electric 1401-N0101-02 1 SAC $26A Hose Assembly - Turbo Assembly to Thermostat/Coolant Valve 1470-N0101-02 1 SAC $

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

Ma

T1 or OEM Total Manufacturing Cost: $30.23 $1.94 $3.50 $35.68 $0.00 $0.00 $0.00 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0

(SAC) &T1 or OEM Mark-Up Values: (29.49) ----- ----- ----- $0.00 $0.00 $0.00 $0.00 $

Base Cost Impact to Vehicle: $0.74 $1.94 $3.50 $6.19 $0.00 $0.00 $0.00 $0.00 $

Packaging Calculations 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

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 1 

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

O

Pal

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS 

10

9,574

47

450,000

1

450,000

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-14, 9 of 9
Appendix G.1 - Subsystem 15

Air Induction Charging Subsystem

 Case Study #0101

MAQS Worksheets

File:15 Air Induction Charging System 040109A.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-15, 1 of 16
Turbo Assembly 1501 Rev 5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Turbo Charging Assembly Part Number: 1501-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) 

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

1A Block Turbo shaft support - cooling & lub 1201-N0101-01-10 1 Subassembly Center Support Block T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 177 4 1 8 0.000 $0.00 $35.51 $30.00 $240.00 $0.00 $0.80 $1.35 $2.15 0.00% 0.00% 2A Housing Turbo Exhaust 1201-N0101-01-09 1 Subassembly Exhaust Housing T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 180 2 1 3 0.000 $0.00 $35.51 $15.00 $45.00 $0.00 $0.39 $0.25 $0.64 0.00% 0.00% 3A Final Assembly Line 1501-N0101-01 1 Final Product Assembly & Test T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 180 11 1 13 0.000 $0.00 $35.51 $15.00 $195.00 $0.00 $2.17 $1.08 $3.25 0.00% 0.00% 4A Turbine Shaft Assembly - Welded 1201-N0101-01-01-24-01 1

Electron Beam Weld Turbine Impeller to Shaft and Grind Profile

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 180 1 1 2 0.000 $0.00 $35.51 $30.00 $60.00 $0.00 $0.20 $0.33 $0.53 0.00% 0.00% 

5A Turbo Assembly Center Housing Rotating Assembly (CHRA) Balancing 1201-N0101-01-01-24 1 High Speed Dynamic Balancing T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, HC, Base 180 4.5 3 1 0.000 $0.00 $35.51 $45.00 $135.00 $0.00 $0.89 $0.75 $1.64 10.00% 0.00% 

Purchase Part - High Impact Item (Full Cost Mapping)

1A Housing Turbo Intake Casting 1201-N0101-01-07-01-2 1 Cast Intake Housing T2/T3 Sand Cast, MSMC Aluminum-A319-T5, Cast Mold/Cast/Sinter Operator Sand Cast, HMC 120 6 1 1 2.200 $1.15 $43.52 $150.07 $150.07 $2.53 $2.18 $1.25 $5.96 5.00% 6.50% 1B Housing Turbo Intake Casting 1201-N0101-01-07-01-1 1 T5 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 125 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.37 $0.80 $1.17 0.50% 6.50% 

1C Housing Turbo Intake Casting 1201-N0101-01-07-01 1 Machine Intake Housing T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MHC 119 3 7 1 0.000 $0.00 $35.70 $45.00 $315.00 $0.00 $0.90 $2.64 $3.53 0.50% 6.50% 

2A Block Center Bearing Support 1201-N0101-01-30-02 1 Sand Casting T2/T3 Sand Cast, MSMC SiMo Ductile Iron, Cast Mold/Cast/Sinter Operator Sand Cast, HMC 160 9 1 1 3.500 $0.60 $43.52 $150.07 $150.07 $2.10 $2.45 $0.94 $5.49 5.00% 6.50% 2B Block Center Bearing Support 1201-N0101-01-30-01 1 T5 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 167 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.28 $0.60 $0.88 0.50% 6.50% 

2C Block Center Bearing Support 1201-N0101-01-30 1 Critical Faces Machine T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MHC 122 4 8 1 0.000 $0.00 $35.70 $45.00 $360.00 $0.00 $1.18 $2.96 $4.14 0.50% 6.50% 

3A Housing Turbo Exhaust 1201-N0101-01-09-01-02 1 Sand Casting T2/T3 Sand Cast, MSMC NiResist Iron, D5S, Cast Mold/Cast/Sinter Operator Sand Cast, HMC 120 6 1 1 6.890 $3.50 $43.52 $150.07 $150.07 $24.12 $2.18 $1.25 $27.54 5.00% 6.50% 3B Housing Turbo Intake Casting 1201-N0101-01-09-01-01 1 T5 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 114 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.41 $0.88 $1.28 0.50% 6.50% 

3C Housing Turbo Exhaust 1201-N0101-01-09-01 1 Machine Casting T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MHC, PREM. 114 3 6 1 0.000 $0.00 $35.70 $55.00 $330.00 $0.00 $0.94 $2.90 $3.84 0.50% 6.50% 

4A Support Plate intake side 1201-N0101-01-26-02 1 Diecasting T2/T3 Diecast, SSLC Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC 275 1 1 1 0.421 $1.10 $43.52 $100.05 $100.05 $0.46 $0.16 $0.36 $0.99 5.00% 6.00% 4B Support Plate intake side 1201-N0101-01-26-01 1 T5 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 267 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.17 $0.38 $0.55 0.50% 6.50% 

4C Support Plate intake side 1201-N0101-01-26 1 Machine Casting T2/T3 CNC Turning, SSLC Not Applicable CNC Operator CNC Turning, MC 129 1 2 1 0.000 $0.00 $35.70 $45.00 $90.00 $0.00 $0.28 $0.70 $0.98 0.30% 6.00% 

5A Heat Shield Exhaust shaft seal 1201-N0101-01-29 1 Stamp T2/T3 Stamp/Form, SSLC Inconel-713C, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 621 0.5 1 1 0.029 $6.00 $42.18 $100.10 $100.10 $0.17 $0.03 $0.16 $0.37 0.30% 6.00% 6A Anti-rotate plate - bushing 1201-N0101-01-34 1 Stamp T2/T3 Stamp/Form, SSLC SPR-Steel, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 720 0.5 1 1 0.005 $0.65 $42.18 $100.10 $100.10 $0.00 $0.03 $0.14 $0.17 0.30% 6.00% 7A Plate Brass Oil Diverter 1201-N0101-01-19-1 1 Stamp Part T2/T3 Stamp/Form, SSLC Bronze-89320, Bar Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 679 0.5 1 1 0.027 $2.56 $42.18 $100.10 $100.10 $0.07 $0.03 $0.15 $0.25 0.30% 6.00% 7B Plate Brass Oil Diverter 1201-N0101-01-19 1 Machine Oil Pass Through T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, LMC 257 0.25 1 2 0.000 $0.00 $35.70 $25.00 $50.00 $0.00 $0.03 $0.19 $0.23 0.50% 6.50% 8A Bushing - Turbine Shaft 1201-N0101-01-32 1 Screw Machine T2/T3 CNC Turning, MSMC Bronze-89320, Bar CNC Operator S-CNC Turning, HC 117 1 2.5 1 0.070 $2.56 $35.70 $85.00 $212.50 $0.18 $0.31 $1.82 $2.30 0.50% 6.50% 9A Seal Carrier support plate mount 1201-N0101-01-27-01 1 Screw Machine T2/T3 CNC Turning, MSMC A-Steel-4140, Bar CNC Operator S-CNC Turning, LC 160 1 2 1 0.040 $0.78 $35.70 $35.00 $70.00 $0.03 $0.22 $0.44 $0.69 0.50% 6.50% 

10A Valve Exhaust Dump 1201-N0101-01-09-01-05-02 1 Investment Cast T2/T3 Invest. Cast, LSHC Nickel Alloy Gen, Cast Mold/Cast/Sinter Operator Invest. Cast, HMC 120 7 1 1 0.150 $5.00 $43.52 $150.08 $150.08 $0.75 $2.54 $1.25 $4.54 5.00% 7.00% 10B Valve Exhaust Dump 1201-N0101-01-09-01-05-01 1 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 118 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.39 $0.84 $1.24 0.50% 6.50% 

10C Valve Exhaust Dump 1201-N0101-01-09-01-05 1 Machine T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, LMC, PREM. 180 0.5 1 1 0.000 $0.00 $35.70 $35.00 $35.00 $0.00 $0.10 $0.19 $0.29 0.50% 6.50% 

11A Arm - Valve to Shaft 1201-N0101-01-09-01-06-02 1 Investment Cast T2/T3 Invest. Cast, LSHC Nickel Alloy Gen, Cast Mold/Cast/Sinter Operator Invest. Cast, HMC 120 7 1 1 0.153 $5.00 $43.52 $150.08 $150.08 $0.77 $2.54 $1.25 $4.55 5.00% 7.00% 11B Arm - Valve to Shaft 1201-N0101-01-09-01-06-01 1 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 118 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.39 $0.84 $1.24 0.50% 6.50% 

11C Arm - Valve to Shaft 1201-N0101-01-09-01-06 1 Machine T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, LMC, PREM. 120 0.5 1 1 0.000 $0.00 $35.70 $35.00 $35.00 $0.00 $0.15 $0.29 $0.44 0.50% 6.50% 

12A Block control rod attachment 1201-N0101-01-09-01-10 1 Permanent Cast T2/T3 Perm. Cast, SSLC S-Steel-310, Cast Mold/Cast/Sinter Operator Perm. Cast, LMC 960 3 1 1 0.042 $2.40 $43.52 $100.06 $100.06 $0.10 $0.14 $0.10 $0.34 5.00% 6.00% 12B Block control rod attachment 1201-N0101-01-09-01-10 1 Machine T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, LMC, PREM. 200 0.5 1 1 0.000 $0.00 $35.70 $35.00 $35.00 $0.00 $0.09 $0.18 $0.26 0.50% 6.50% 13A Arm Dump Valve Control 1201-N0101-01-09-01-08 1 Permanent Cast T2/T3 Perm. Cast, SSLC S-Steel-310, Cast Mold/Cast/Sinter Operator Perm. Cast, LMC 960 3 1 1 0.050 $2.40 $43.52 $100.06 $100.06 $0.12 $0.14 $0.10 $0.36 5.00% 6.00% 14A Impeller Intake 1201-N0101-01-16-03 1 Rubber/Plaster Mold T2/T3 Invest. Cast, LSHC Aluminum-356-T6, Cast Mold/Cast/Sinter Operator Invest. Cast, HMC 180 5 1.25 1 0.064 $1.20 $43.52 $150.08 $187.60 $0.08 $1.21 $1.04 $2.33 25.00% 7.00% 14B Impeller Intake 1201-N0101-01-16-02 1 T6 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 174 1 1.5 1 0.000 $0.00 $46.52 $100.00 $150.00 $0.00 $0.27 $0.86 $1.13 20.00% 6.50% 

14C Impeller Intake 1201-N0101-01-16-01 1 Machine T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, MC 164 1 2.5 1 0.000 $0.00 $35.70 $45.00 $112.50 $0.00 $0.22 $0.69 $0.91 20.00% 6.50% 14D Impeller Intake 1201-N0101-01-16 1 2 Plane Dynamic Balance T2/T3 CNC Turning, MSMC Not Applicable Precision Assembly Balancing, SMS, MHC 180 4.5 3 1 0.000 $0.00 $25.74 $45.00 $135.00 $0.00 $0.64 $0.75 $1.39 20.00% 6.50% 

15A Turbine Wheel 1201-N0101-01-01-24-05 1 Investment Cast T2/T3 Invest. Cast, LSHC Inconel-713, Cast Mold/Cast/Sinter Operator Invest. Cast, HMC 180 9 1.5 1 0.075 $6.00 $43.52 $150.08 $225.12 $0.45 $2.18 $1.25 $3.88 25.00% 7.00% 15B Turbine Wheel 1201-N0101-01-01-24-04 1 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 178 1 1.5 1 0.000 $0.00 $46.52 $100.00 $150.00 $0.00 $0.26 $0.84 $1.11 20.00% 6.50% 

15C Turbine Wheel 1201-N0101-01-01-24-03 1 Machine T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, MC 180 0.5 1 1 0.000 $0.00 $35.70 $45.00 $45.00 $0.00 $0.10 $0.25 $0.35 20.00% 6.50% 15D Turbine Wheel 1201-N0101-01-01-24-02 1 2 Plane Dynamic Balance T2/T3 CNC Turning, MSMC Not Applicable Precision Assembly Balancing, SMS, MHC 180 4.5 3 1 0.000 $0.00 $25.74 $45.00 $135.00 $0.00 $0.64 $0.75 $1.39 20.00% 6.50% 

16A Turnbine Shaft 1201-N0101-01-01-24-03-01 1 Machine & Grind Shaft T2/T3 CNC Turning, MSMC A-Steel-4140, Bar CNC Operator S-CNC Turning, MC 176 1 2.5 1 0.255 $0.78 $35.70 $55.00 $137.50 $0.20 $0.20 $0.78 $1.18 10.00% 6.50% 

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

Full Quote Modification Quote Differential Quote (Quote Summary includes 

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 APPENDIX G.1-15, 2 of 16
Turbo Assembly 1501 Rev 5 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Turbo Charging Assembly Part Number: 1501-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) 

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

Full Quote Modification Quote Differential Quote (Quote Summary includes 

16B Turnbine Shaft 1201-N0101-01-01-24-03 1 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 250 1 1 1 0.000 $0.00 $46.52 $100.00 $100.00 $0.00 $0.19 $0.40 $0.59 10.00% 6.50% 

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

1A Seal Shaft exhaust end 1201-N0101-01-25 1 (M2 Tool Steel & Inconel) S 

2A Plug Threaded 1201-N0101-01-30-03 2 S 3A Sleeve Shaft Bushing 1201-N0101-01-30-02 1 S 4A Snap Ring - Bearing retainer 1201-N0101-01-31 1 S 

5a C-Clip - Bushing Retainer 1201-N0101-01-33 1 S 

6A O-Ring Inner ID of support plate to block 1201-N0101-01-21 1 S 7A Spacer Oil Diverter Plates 1201-N0101-01-20 1 S 8A Seal - Shaft Support Plate to seal carrier 1201-N0101-01-28 1 S 9A Nut turbine Shaft 1201-N0101-01-15 1 S 

10A O-Ring Intake Housing to block seal 1201-N0101-01-14 1 S 11A Bolt Intake Housing to Shaft Housing 1201-N0101-01-04 4 S 12A Pin Housing to Center Block Locating 1201-N0101-01-09-01-13 1 S 13A Bushing Dump Valve Shaft 1201-N0101-01-09-01-09 1 (Specialized Alloy or Nitrided) S 14A Washer - Valve Retainer 1201-N0101-01-09-01-07 1 Stainless S 15A Washer Block retainer 1201-N0101-01-09-01-11 1 Steel S 16A Stud Turbo to Exhaust Manifold 1201-N0101-01-11 4 Stainless (A286) S 17A Stud - Catalytic Coverter 1280-N0101-07 3 Stainless (A286) S 18A Clamp Exhaust housing to shaft block 1201-N0101-01-08 1 Stainless S 19A Nut Saddle Clamp 1201-N0101-01-13 1 Stainless S 20A Solenoid Intake Bypass 1201-N0101-01-05 1 S 21A Gasket Intake Housing Solenoid 1201-N0101-01-12 1 S 22A Bolt Solenoid to Intake Housing 1201-N0101-01-06 3 S 23A Diaphram Exhaust dump valve 1201-N0101-01-01 1 S 24A Nut Exhaust Diaphram Shaft 1201-N0101-01-02 2 S 25A Nut Diaphram to Intake Housing 1201-N0101-01-03 2 S 26A Gasket - Turbo Inlet to Exhaust Manifold 1285-N0101-01 1 S 27A Nut - Turbo to exhaust Manifold 1280-N0101-10 4 S 28A Tag ID 1201-N0101-01-07-02 1 S 29A Rivet ID Tag 1201-N0101-01-07-03 1 S 

0 

Material Labor Burden TMC Scrap SG&A 

T1 or OEM Total Manufacturing Cost: $49.30 $26.79 $33.75 $109.84 $5.45 $5.38 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.89 $8.87 

Base Cost Impact to Vehicle: $49.30 $26.79 $33.75 $109.84 $6.34 $14.2

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

Rack/Pallet Investment Amortization: $0.108 $215,426 0.00% 2,250,000 60 5.00% $300 718 

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 #

Pads 

Pallet/Ra

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

Packaging Cost Total: $0.108

 PACKAGING CALCULATIONS: Packaging Type: Option #2Part Size: 300x200X190Parts/Layer: 4x5Number of Layers: 4

"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:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 APPENDIX G.1-15, 3 of 16
Cooler Assembly 1505 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Loc

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Loc

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Me

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specific

Component Description: Cooler Assembly - Charged Air Part Number: 1505-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark-up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

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

1B Tube with cooling fins 1505-N0101-01-1-1 5

Insert Cooling Fins, Laser weld seem on Tube, Pressure Test.

S Not Applicable General Assembly Mech. Assembly, MC 566 2 0.000 $0.00 $35.51 $125.19 $0.00 $0.13 $0.22 $0.35 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.35 

2C Cooler Assembly - Charged Air Heat Exchanger 1505-N0101-01-01-02 1

Assemble Tube Assemblies, 

Outer Fins, Top/Bottom Plates and Header Plates, Gasket & End Caps

S Not Applicable General Assembly Mech. Assembly, MC 116 5 0.000 $0.00 $35.51 $125.19 $0.00 $1.53 $1.08 $2.61 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.61 

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube 1505-N0101-01-1-2 5 Pre-Form & Cut to Length S Aluminum-3003/4047A, Cladding Cut/Punch/Forming Operator Stamp/Form, SMS, MHC 514 0.5 0.320 $1.65 $42.18 $125.10 $0.53 $0.04 $0.24 $0.81 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.81 2A Cooling Fins Inside Tube 1505-N0101-01-1-3-01 5 Form and Cut to Length S Aluminum-3003/4047A, Cladding Cut/Punch/Forming Operator Stamp/Form, SMS, MHC 720 0.5 0.100 $1.65 $42.18 $125.10 $0.17 $0.03 $0.17 $0.37 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.37 3A Top/Bottom Plates 1505-N0101-01-1-4 2 Form and Cut to Length S Aluminum-3003/4047A, Cladding Cut/Punch/Forming Operator Stamp/Form, SMS, MHC 720 0.5 0.110 $1.65 $42.18 $125.10 $0.18 $0.03 $0.17 $0.38 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.38 4A Cooling Fins Outer 1505-N0101-01-1-5--01 6 Lance, Form, Cut to length S Aluminum-3003/4047A, Cladding Cut/Punch/Forming Operator Stamp/Form, SMS, MHC 720 0.5 0.140 $1.65 $42.18 $125.10 $0.23 $0.03 $0.17 $0.43 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.43 4B Header Plate 1505-N0101-01-1-6-01 2 Pierce and Form S

Aluminum3003/4047B, Cladding

Cut/Punch/Forming Operator Stamp/Form, SMS, MHC 529 0.25 0.130 $2.10 $42.18 $125.10 $0.27 $0.02 $0.24 $0.53 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.53 

5A End Cap R Cooler Assembly - Charged Air Heat Exchange 1505-N0101-01-2 1 Injection Mold S Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 655 0.5 0.254 $1.54 $43.52 $100.01 $0.39 $0.03 $0.15 $0.58 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.58 5B End Cap L Cooler Assembly - Charged Air Heat Exchange 1505-N0101-01-3 1 Injection Mold S Nylon66-50GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 643 0.5 0.299 $1.54 $43.52 $100.01 $0.46 $0.03 $0.16 $0.65 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.65 

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

Supplier 

Account 

Cost

Purchase Price/ 

Unit

Purchase Price 

Net, PIA

Pu

Ne

1A Gasket End Cap 1505-N0101-01-4 2 S $0.00 $0.15 $0.00 

0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 0 $0.00 $0.00 $0.00 

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

T1 or OEM Total Manufacturing Cost: $6.91 $2.85 $6.44 $16.20 $0.00 $0.00 $0.00 $0.00 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.00% 6.00% 2.00% 14.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.08 $0.97 $0.97 $0.32 $2.35

Base Cost Impact to Vehicle: $6.91 $2.85 $6.44 $16.20 $0.08 $0.97 $0.97 $0.32 $2.35 

Packaging Cost: 

Net Cost Impact to Vehicle: 

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL CO

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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

1

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 APpendix G.1-15, 4 of 16
Cooler Assembly 1505 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Loc

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Loc

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Me

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specific

Component Description: Cooler Assembly - Charged Air Part Number: 1505-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark-up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL CO

Packaging Calculations 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 

In-transit 

Inventory 

Requirements 

(Weeks)

Supplier, 

Customer and Intransit Inventory 

Requirements 

(Parts)

Rack/Pallet Investment Amortization: $0.096 $382,979 0.00% 4,500,000 60 5.00% $420 912 63 6 57447

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: $0.096

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 APpendix G.1-15, 5 of 16
Tube Ass'y-Waste Gate 1570A Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Location

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Location

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Method

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specification

Component Description: Tube Assembly - Turbo Waste Gate Pneumatic Control Part Number: 1570-N0101-03 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 3 = 

Total 2 * Qty per Ass'y

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

1A Tube Reservoir to Solenoid 1770-N0101-03-1 1 Assemble sheathing and glue on end connections. S Not Applicable General Assembly Mech. Assembly, LC 180 1 0.000 $0.00 $35.51 $100.19 $0.00 $0.20 $0.56 $0.75 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.75 $0.752A Tube Reservoir to Pump 1770-N0101-03-2 1 Assemble sheathing and glue on end connections. S Not Applicable General Assembly Mech. Assembly, LC 157 1 0.000 $0.00 $35.51 $100.19 $0.00 $0.23 $0.64 $0.87 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.87 $0.873A Tube - Sol to Wastegate 1770-N0101-03-4 1 Assemble sheathing S Not Applicable General Assembly Mech. Assembly, LC 300 1 0.000 $0.00 $35.51 $100.19 $0.00 $0.12 $0.33 $0.45 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.45 $0.45

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube Reservoir to Solenoid 1770-N0101-03-1-1 1 Extrude and Form S Nylon12, Inject. Extruding/Drawing Operator Comp./Ext. Mold, LMC 400 1.5 0.009 $3.03 $54.35 $100.04 $0.03 $0.20 $0.25 $0.48 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.48 $0.482A Tube Preformed 1770-N0101-03-2-1 1 Extrude and Form S Nylon12, Inject. Extruding/Drawing Operator Comp./Ext. Mold, LMC 257 1.5 0.020 $3.03 $54.35 $100.04 $0.06 $0.32 $0.39 $0.77 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.77 $0.773A Tube - Sol to Wastegate 1770-N0101-03-4-1 1 Extrude S Thermoset-SBR Extruding/Drawing Operator Comp./Ext. Mold, LMC 514 0.5 0.095 $1.32 $54.35 $100.04 $0.13 $0.05 $0.19 $0.37 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.37 $0.37

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1A Hose Tube end connections 1770-N0101-03-1-2 4 Rubber S $0.00 $0.04 $0.00 $0.16

2A Sheath Tube-Short 1770-N0101-03-1-3 1 Nylon S $0.00 $0.20 $0.00 $0.203A Sheath Tube - medium 1770-N0101-03-2-2 1 Nylon S $0.00 $0.50 $0.00 $0.504A Sheath Tube-Long 1770-N0101-03-4-2 1 Nylon S $0.00 $0.60 $0.00 $0.605A Zip Tie - tube to tube 1770-N0101-03-3 3 S $0.00 $0.02 $0.00 $0.066A Zip Tie Edge Bitter - tube to tube 1770-N0101-03-6 1 S $0.00 $0.12 $0.00 $0.127A Isolator/Hose wrap 1770-N0101-03-5 1 S $0.00 $0.08 $0.00 $0.08

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Mark-up $5.41

T1 or OEM Total Manufacturing Cost: $1.93 $1.12 $2.36 $5.41 $0.00 $0.00 $0.00 $0.00 $0.00 $5.41

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 ----- ----- ----- $0.02 $0.32 $0.22 $0.05 $0.61

Base Cost Impact to Vehicle: $1.93 $1.12 $2.36 $5.41 $0.02 $0.32 $0.22 $0.05 $0.61 $6.03 

Packaging Cost: $0.10

Net Cost Impact to Vehicle: $6.12

Packaging Calculations 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 

Requiremen

ts (Weeks)

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Parts)

Rack/Pallet Investment Amortization: $0.013 $26,596 0.00% 2,250,000 60 5.00% $200 133 432 6 57447

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: $0.09 $1.00 10 $3.00 9 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.099

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS 

Packaging Opdividers.12 Cells per L9 Layers.Total # of Part

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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

1

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-15, 6 of 16
Tube Assembly-Inlet 1570B Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Location

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Location

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Method

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specification

Component Description: Tube Ass'y w. Vehicle Tie Down Canister, Air Cooler Inlet Part Number: 1570-N0101-20/21/22 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 3 = 

Total 2 * Qty per Ass'y

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

1A Resonator Tube Sub-Assembly 1570-N0101-21 1 Spin Weld Housing Inner to Baffle Inner S Not Applicable General Assembly Mech. Assembly, LC 300 3 0.000 $0.00 $35.51 $100.19 $0.00 $0.36 $0.33 $0.69 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.69 $0.692A Tube Ass'y w. Vehicle Tie Down Canister, Air Cooler 1570-N0101-19 1 Assembly Tubes to Resonator S Not Applicable General Assembly Mech. Assembly, LC 200 3 0.000 $0.00 $35.51 $100.19 $0.00 $0.53 $0.50 $1.03 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.03 $1.03

Purchase Part - High Impact Item (Full Cost Mapping)

1A Hose Long 1570-N0101-19-2 1 Extrude and Form S SBR-Fiber Rein., Extruded Extruding/Drawing Operator Comp./Ext. Mold, LMC 295 1.5 0.691 $1.85 $54.35 $100.04 $1.28 $0.28 $0.34 $1.89 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.89 $1.891B Hose Long w. Overmold Clamp 1570-N0101-19-2 1 Overmold Clamp to Hose S Not Applicable Extruding/Drawing Operator Comp./Ext. Mold, LMC 240 1 0.000 $0.00 $54.35 $100.04 $0.00 $0.23 $0.42 $0.64 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.64 $0.642A Hose Short Preformed 1570-N0101-19-6 1 Extrude and Form S SBR-Fiber Rein., Extruded Extruding/Drawing Operator Comp./Ext. Mold, LMC 450 1.5 0.387 $1.85 $54.35 $100.04 $0.71 $0.18 $0.22 $1.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.12 $1.123A Housing Outer Shell 1570-N0101-19-4-1 1 Injection Mold S Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 554 0.25 0.513 $1.54 $43.52 $100.01 $0.79 $0.02 $0.18 $0.99 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.99 $0.993B Baffle Inner Tube & End Cap 1570-N0101-19-4-2 1 Injection Mold S Nylon66-50GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 610 0.25 0.203 $1.54 $43.52 $100.01 $0.31 $0.02 $0.16 $0.49 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.49 $0.49

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1A Hose Clamp 1570-N0101-19-3 3 2" S $0.00 $0.27 $0.00 $0.81

2A Sleeve Tube Anti-Crush 1570-N0101-19-4-3 2 Steel, Nickel/Zinc Plate S $0.00 $0.30 $0.00 $0.603A Hose clamp 1570-N0101-19-8 1 2" w. Retention Teeth S $0.00 $0.35 $0.00 $0.354A Grommet Fastener Isolator 1570-N0101-19-4-4 1 S $0.00 $0.08 $0.00 $0.085A Sleeve Anti-Crush, Fastener 1570-N0101-19-4-5 1 S $0.00 $0.05 $0.00 $0.05

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Mark-up $8.75

T1 or OEM Total Manufacturing Cost: $4.98 $1.61 $2.16 $8.75 $0.00 $0.00 $0.00 $0.00 $0.00 $8.75

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 ----- ----- ----- $0.03 $0.53 $0.35 $0.09 $0.99

Base Cost Impact to Vehicle: $4.98 $1.61 $2.16 $8.75 $0.03 $0.53 $0.35 $0.09 $0.99 $9.74 

Packaging Cost: $0.08

Net Cost Impact to Vehicle: $9.82

Packaging Calculations 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 

Requiremen

ts (Weeks)

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Parts)

Rack/Pallet Investment Amortization: $0.030 $59,840 0.00% 2,250,000 60 5.00% $200 299 192 6 57447

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: $0.05 $1.00 9 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.077

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS 

Option #1 with Part Size =600Parts per Pallelayers= 192 pa

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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.

3

1

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-15, 7 of 16
Tube Assembly-Outlet-1570C Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Location

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Location

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Method

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specification

Component Description: Tube Ass'y w. Vehicle Tie Down Canister, Air Cooler Outlet Part Number: 1570-N0101-30 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 3 = 

Total 2 * Qty per Ass'y

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

1A Tube 1570-N0101-30-5 1 Install Inserts and Grommets S Not Applicable General Assembly Mech. Assembly, LC 240 5 0.000 $0.00 $35.51 $100.19 $0.00 $0.74 $0.42 $1.16 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.16 $1.16

2 Tube - Charge Air Cooler Outlet 1570-N0101-30 1 Install Hose, Clamp S Not Applicable General Assembly Mech. Assembly, LC 180 2 0.000 $0.00 $35.51 $100.19 $0.00 $0.39 $0.56 $0.95 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.95 $0.95

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube 1570-N0101-30-5 1 Friction Weld S Not Applicable Mold/Cast/Sinter Operator Inject. Mold, SMS 180 3 0.000 $0.00 $43.52 $100.01 $0.00 $0.73 $0.56 $1.28 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.28 $1.281B Tube 1570-N0101-30-5-2 1 Extrude & Blow Form Tube S Nylon6-15GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 145 1 1.612 $1.59 $43.52 $100.01 $2.56 $0.30 $0.69 $3.55 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $3.55 $3.552A Tube Attachment #1 1570-N0101-30-5-31 1 Injection Mold S Nylon6-15GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 720 0.25 0.015 $1.59 $43.52 $100.01 $0.02 $0.02 $0.14 $0.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.18 $0.183A Tube Attachment #2 1570-N0101-30-5-32 1 Injection Mold S Nylon6-15GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 720 0.25 0.015 $1.59 $43.52 $100.01 $0.02 $0.02 $0.14 $0.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.18 $0.184A Tube Attachment #3 1570-N0101-30-5-33 1 Injection Mold S Nylon6-15GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 720 0.25 0.015 $1.59 $43.52 $100.01 $0.02 $0.02 $0.14 $0.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.18 $0.185A Hose preformed 1570-N0101-30-3 1 Extrude and Form S SBR-Fiber Rein., ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC 367 1.5 0.676 $1.85 $54.35 $100.04 $1.25 $0.22 $0.27 $1.74 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.74 $1.745B Hose w/Clamps 1570-N0101-30-1 1 Overmold Clamp to Hose S Not Applicable Extruding/Drawing Operator Comp./Ext. Mold, LMC 240 1 0.000 $0.00 $54.35 $100.04 $0.00 $0.23 $0.42 $0.64 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.64 $0.64

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1A Insert Brass Threaded 1570-N0101-30-6 1 S $0.00 $0.04 $0.00 $0.04

2A Sleeve Tube Anti-Crush 1570-N0101-19-4-3 2 S $0.00 $0.30 $0.00 $0.603A Grommet Fastener Isolator 1570-N0101-19-4-4 1 S $0.00 $0.08 $0.00 $0.084A Sleeve Anti-Crush, Fastener 1570-N0101-19-4-5 1 S $0.00 $0.05 $0.00 $0.055A Nut - Flag w/Isolator 1570-N0101-30-7 1 S $0.00 $0.25 $0.00 $0.256A Sleeve Anti Crush 1570-N0101-30-8 1 S $0.00 $0.30 $0.00 $0.307A Hose Clamp 1570-N0101-30-4 2 S $0.00 $0.29 $0.00 $0.588A Sensor - Intake Temperature, Outlet Charged Air Co 1599-N0101-03 1 S $0.00 $5.00 $0.00 $5.009A Bolt - Sensor, Charge Air Temperature 1580-N0101-10 1 S $0.00 $0.04 $0.00 $0.04

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Mark-up $16.81

T1 or OEM Total Manufacturing Cost: $10.83 $2.65 $3.32 $16.81 $0.00 $0.00 $0.00 $0.00 $0.00 $16.81

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 ----- ----- ----- $0.05 $1.01 $0.67 $0.17 $1.90

Base Cost Impact to Vehicle: $10.83 $2.65 $3.32 $16.81 $0.05 $1.01 $0.67 $0.17 $1.90 $18.70 

Packaging Cost: $0.06

Net Cost Impact to Vehicle: $18.76

Packaging Calculations 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 

Requiremen

ts (Weeks)

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Parts)

Rack/Pallet Investment Amortization: $0.057 $227,394 0.00% 4,500,000 60 5.00% $380 598 96 6 57447

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: $0.057

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS 

Pallet Option #Part Size = 60Parts per PalleLayers = 96 Pa

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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.

3

1

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-15, 8 of 16
Tube Assembly-Outlet-1570D Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Location

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Location

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Method

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specification

Component Description: Tube - Elbow, Upper to Charged Air Coupler By-Pass Part Number: 1570-N0101-40 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 3 = 

Total 2 * Qty per Ass'y

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

Tube - Elbow, Upper to Charged Air Coupler ByPas 1570-N0101-40 1 Crimp End Hose Piece onto Hose and Add O-Ring S Not Applicable General Assembly Mech. Assembly, LC 240 1 0.000 $0.00 $35.51 $100.19 $0.00 $0.15 $0.42 $0.57 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.57 $0.57

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube (Hose) preformed 1570-N0101-40-1 1 Extrude and Form S SBR-Fiber Rein., Extruded Extruding/Drawing Operator Comp./Ext. Mold, LMC 400 1.5 0.620 $1.85 $54.35 $100.04 $1.15 $0.20 $0.25 $1.60 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.60 $1.601B Tube (Hose) w/Clamps 1570-N0101-40-1-1 1 Overmold Clamp to Hose S Not Applicable Extruding/Drawing Operator Comp./Ext. Mold, LMC 240 1 0.000 $0.00 $54.35 $100.04 $0.00 $0.23 $0.42 $0.64 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.64 $0.64

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

Hose Clamp 1570-N0101-40-2 1 S $0.00 $0.25 $0.00 $0.25

Hose end piece 1570-N0101-40-3 1 S $0.00 $0.75 $0.00 $0.75O-ring Seal Tube OD 1570-N0101-40-4 1 S $0.00 $0.11 $0.00 $0.11

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

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Mark-up $3.92

T1 or OEM Total Manufacturing Cost: $2.26 $0.58 $1.08 $3.92 $0.00 $0.00 $0.00 $0.00 $0.00 $3.92

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 $0.24 $0.16 $0.04 $0.44

Base Cost Impact to Vehicle: $2.26 $0.58 $1.08 $3.92 $0.01 $0.24 $0.16 $0.04 $0.44 $4.36 

Packaging Cost: $0.03

Net Cost Impact to Vehicle: $4.39

Packaging Calculations 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 

Requiremen

ts (Weeks)

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Parts)

Rack/Pallet Investment Amortization: $0.010 $19,947 0.00% 2,250,000 60 5.00% $200 100 576 6 57447

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: $0.02 $1.00 10 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.027

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS 

Package OptioPart Size = 20Each Layer = 4 Number of LayTotal Parts pe

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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

1

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-15, 9 of 16
Tube Inlet ETB-1570 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Loca

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Loca

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Met

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specifica

Component Description: Part Number: 1570-N0101-41/42/43/44 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark-up Rate Total Mark-up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 2 * Qty per Ass'y

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

1A Flex Tube Silencer to Environment 1070-N0101-05-3 (1570-N0101-44) 1 Heat Stake Cap to Flex Tube and add foam. S Not Applicable General Assembly Mech. Assembly, LC 240 1 0.000 $0.00 $35.51 $100.19 $0.00 $0.15 $0.42 $0.57 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.57 $2A Silencer - Charge Air By-Pass 1070-N0101-05-2 (1599-N0101-04) 1 Insert Inner Baffle and Vibration Weld Housing S Not Applicable General Assembly Mech. Assembly, LC 240 1 0.000 $0.00 $35.51 $100.19 $0.00 $0.15 $0.42 $0.57 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.57 $3A Hose Ass'y Silencer to Y Couple (Tube - Charged Air Bypass to Silencer) 1070-N0101-05-5 (1570-N0101-43) 1 Assemble Protective Sheath and Isolator S Not Applicable General Assembly Mech. Assembly, LC 300 1 0.000 $0.00 $35.51 $100.19 $0.00 $0.12 $0.33 $0.45 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.45 $4A Tube Inlet to throttle body 1070-N0101-05 (1570-N0101-42) 1 Assemble Individual Tube Assemblies with clamps S Not Applicable General Assembly Mech. Assembly, LC 120 4 0.000 $0.00 $35.51 $100.19 $0.00 $1.18 $0.83 $2.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.02 $

Purchase Part - High Impact Item (Full Cost Mapping)

1A Tube - Flex Elbow, Silencer to Environment 1070-N0101-05-15-1 (1570-N0101-44) 1 Injection Mold S TPE-PP/EPDM, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 710 1 0.205 $0.99 $43.52 $100.01 $0.20 $0.06 $0.14 $0.41 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.41 $2A Tube - Flex Elbow, Silencer to Environment, Snap 1070-N0101-05-15-2 (1570-N0101-44) 1 Injection Mold S Nylon6-15GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 720 0.5 0.020 $1.59 $43.52 $100.01 $0.03 $0.03 $0.14 $0.20 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.20 $3A Silencer Outer Shell 1070-N0101-05-2-1 1 Injection Mold S PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 509 0.5 0.270 $1.45 $43.52 $100.01 $0.39 $0.04 $0.20 $0.63 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.63 $4A Silencer Inner Baffle 1070-N0101-05-2-1-2-3 1 Injection Mold S PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 986 0.5 0.140 $1.45 $43.52 $100.01 $0.20 $0.02 $0.10 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $5A Silencer End Cap 1070-N0101-05-2-1-2 1 Injection Mold S PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 900 0.5 0.140 $1.45 $43.52 $100.01 $0.20 $0.02 $0.11 $0.34 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.34 $6A Tube (Hose) preformed 1570-N0101-40-1 1 Extrude and Form S SBR-Fiber Rein., ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC 383 1.5 0.380 $1.85 $54.35 $100.04 $0.70 $0.21 $0.26 $1.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.18 $7A Tube Y-Coupler to bypass 1070-N0101-05-8-1 (1570-N0101-41) 1 Injection Mold S Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 923 0.5 0.289 $1.76 $43.52 $100.01 $0.51 $0.02 $0.11 $0.64 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.64 $8A Elbow Coupler Bypass to Throttle (Tube-Elbow Coupler By-Pass to Throttle Body) 1070-N0101-05-10-1 (1570-N0101-42) 1 Extrude and Form S SBR-Fiber Rein., ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC 343 1.5 0.723 $1.85 $54.35 $100.04 $1.34 $0.24 $0.29 $1.87 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.87 $8B Elbow Coupler Bypass to Throttle w. Clamp (Tube-Elbow Coupler By-Pass to Throttle Body) 1070-N0101-05-11 (1570-N0101-42) 1 Overmold Clamp to Hose S Not Applicable Extruding/Drawing Operator Comp./Ext. Mold, LMC 240 1 0.000 $0.00 $54.35 $100.04 $0.00 $0.23 $0.42 $0.64 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.64 $

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase Price 

Net, PIA

Purch

Net, 

1A Seal foam press in place tape style 1070-N0101-05-16 1 S $0.00 $0.10 $0.00 $

2A Grommet - Silencer to Engine 1070-N0101-05-99 1 S $0.00 $0.15 $0.00 $3A Sheath Hose Protection 1070-N0101-05-14 1 S $0.00 $0.38 $0.00 $4A Isolator Hose 1070-N0101-05-7 1 S $0.00 $0.12 $0.00 $5A Hose Clamp lrg end molded in place 1070-N0101-05-12 1 S $0.00 $0.40 $0.00 $

6a Hose Clamp sml end 1070-N0101-05-11 1 S $0.00 $0.27 $0.00 $7a Hose Clamp 1070-N0101-05-4 3 S $0.00 $0.16 $0.00 $

0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $0 $0.00 $0.00 $0.00 $

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Mark- up $1

T1 or OEM Total Manufacturing Cost: $5.48 $2.48 $3.77 $11.73 $0.00 $0.00 $0.00 $0.00 $0.00 $1

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 ----- ----- ----- $0.04 $0.70 $0.47 $0.12 $1.33

Base Cost Impact to Vehicle: $5.48 $2.48 $3.77 $11.73 $0.04 $0.70 $0.47 $0.12 $1.33 $1

Packaging Cost: $

Net Cost Impact to Vehicle: $1

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

Tube: Coupler Y Branch to By-Pass/Elbow Coupler By-Pass to Throttle Body/Elbow Coupler By-Pass to Throttle Body/Tube - Flex Elbow, Silencer to Environment

TOTAL COS

10

9,574

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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

1

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-15, 10 of 16
Tube Inlet ETB-1570 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Loca

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Loca

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Met

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specifica

Component Description: Part Number: 1570-N0101-41/42/43/44 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark-up Rate Total Mark-up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 2 * Qty per Ass'y

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS MARK-UP COSTS

Tube: Coupler Y Branch to By-Pass/Elbow Coupler By-Pass to Throttle Body/Elbow Coupler By-Pass to Throttle Body/Tube - Flex Elbow, Silencer to Environment

TOTAL COS

10

9,574

Packaging Calculations 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 

In-transit 

Inventory 

Requirements 

(Weeks)

Supplier, 

Customer and Intransit Inventory 

Requirements 

(Parts)

Rack/Pallet Investment Amortization: $0.066 $131,649 0.00% 2,250,000 60 5.00% $220 598 96 6 57447

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: $0.066

Pallet OptCell ReturPart Size: Parts/LayeNumber o

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-15, 11 of 16
Bracket-Support Turbo 1575 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Location

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Location

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Method

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specification

Component Description: Bracket - Support, Turbo Assembly Part Number: 1575-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 3 = 

Total 2 * Qty per Ass'y

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

Bracket - Support, Turbo Assembly 1575-N0101-01 (1275-N0101-04) 1 Forging S S-Steel-304, Bar Forging Operator Cold Forge, LMC 257 1 0.649 $1.65 $38.52 $100.09 $1.07 $0.15 $0.39 $1.61 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.61 $1.61

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

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

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Mark-up $1.61

T1 or OEM Total Manufacturing Cost: $1.07 $0.15 $0.39 $1.61 $0.00 $0.00 $0.00 $0.00 $0.00 $1.61

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.30% 6.00% 4.00% 0.00% 10.30%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.10 $0.06 $0.00 $0.17

Base Cost Impact to Vehicle: $1.07 $0.15 $0.39 $1.61 $0.00 $0.10 $0.06 $0.00 $0.17 $1.78 

Packaging Cost: $0.06

Net Cost Impact to Vehicle: $1.84

Packaging Calculations 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 

Requiremen

ts (Weeks)

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Parts)

Rack/Pallet Investment Amortization: $0.001 $1,596 0.00% 2,250,000 60 5.00% $100 16 3600 6 57447

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: $0.06 $0.00 0 $0.00 0 $3.50 60 $0.00 0 $0.00 0

Packaging Cost Total: $0.059

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS 

Packaged in EBoxes(Weight ConsiCard Board Bo($3.50/Box)Parts per Box: Layers/Box = 6Per Pallet (1/2 layer3 layers = 60 B

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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

1

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-15, 12 of 16
Vac. Reservoir 1599 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Location

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Location

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Method

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specification

Component Description: Vacuum Reservoir - Turbo Waste Gate Part Number: 1599-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 3 = 

Total 2 * Qty per Ass'y

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

1A Vacuum Reservoir 7070-N0101-02 (1599-N01010-01) 1 Vibration Weld and Assembly Inserts S Not Applicable General Assembly Mech. Assembly, LC 240 2 0.000 $0.00 $35.51 $100.19 $0.00 $0.30 $0.42 $0.71 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.71 $0.71

Purchase Part - High Impact Item (Full Cost Mapping)

1A Cover - cap: Vacuum Reservoir 7070-N0101-02-1 1 PA6 GF35 S Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 1037 0.5 0.158 $1.76 $43.52 $100.01 $0.28 $0.02 $0.10 $0.40 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.44 $0.442A Base Reservoir: Vacuum Reservoir 7070-N0101-02-2 1 PA6 GF35 S Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 861 0.5 0.454 $1.76 $43.52 $100.01 $0.80 $0.03 $0.12 $0.94 0.30% 6.00% 4.00% 0.00% 10.30% $0.10 $1.04 $1.04

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1A Anti-Crush Sleeves Vacuum Reservoir 7070-N0101-02-3 3 $0.00 $0.04 $0.12 $0.00

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

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Mark-up $2.19

T1 or OEM Total Manufacturing Cost: $1.08 $0.34 $0.63 $2.05 $0.00 $0.08 $0.05 $0.00 $0.14 $2.19

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

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.14 $0.13 $0.05 $0.34

Base Cost Impact to Vehicle: $1.08 $0.34 $0.63 $2.05 $0.01 $0.22 $0.18 $0.05 $0.48 $2.53 

Packaging Cost: $0.10

Net Cost Impact to Vehicle: $2.63

Packaging Calculations 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 

Requiremen

ts (Weeks)

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Parts)

Rack/Pallet Investment Amortization: $0.017 $33,497 0.00% 2,250,000 60 5.00% $200 167 343 6 57447

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: $0.08 $1.00 8 $3.00 7 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.101

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS 

Pallet Option #PadsPart Size:170xParts Layer = Number of Lay

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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

1

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-15, 13 of 16
Valve-Thrust Control 1599 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): OEM Plant Location

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): Supplier Plant Location

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: Shipping Method

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: Packaging Specification

Component Description: Value - Thrust Control, Turbo Waste Gate Pneumatic Control Part Number: 1599-N0101-02 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate Total Mark- up Rate Total Mark- up Cost

Total 2 = 

Total 1 + Total Mark-up

Total 3 = 

Total 2 * Qty per Ass'y

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

Supplier 

Account 

Cost

Purchase 

Price/ Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1A Value - Thrust Control, Turbo Waste Gate Pneumatic Control 1599-N0101-02 1 (Look @ Evaluating as Low Impact Supplier) S $0.00 $5.19 $0.00 $5.19

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

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Mark-up $5.19

T1 or OEM Total Manufacturing Cost: $5.19 $0.00 $0.00 $5.19 $0.00 $0.00 $0.00 $0.00 $0.00 $5.19

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 $0.34 $0.31 $0.13 $0.80

Base Cost Impact to Vehicle: $5.19 $0.00 $0.00 $5.19 $0.03 $0.34 $0.31 $0.13 $0.80 $5.99 

Packaging Cost: $0.02

Net Cost Impact to Vehicle: $6.02

Packaging Calculations 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 

Requiremen

ts (Weeks)

Supplier, 

Customer 

and Intransit 

Inventory 

Requiremen

ts (Parts)

Rack/Pallet Investment Amortization: $0.024 $48,980 0.00% 2,250,000 60 5.00% $4,420 11 5184 6 57447

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: $0.024

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS 

Packaging OpTraysPart Size 80x9Parts/Layer = Number of Lay

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly."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

1

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-15, 14 of 16
Engine Assembly 1500 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Engine And Vehicle Assembly Part Number: 1500-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) 

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

1A Turbo Charging Assembly 1501-N0101-01 1 Mount Turbo Assembly to Intake Manifold, 4 Nuts OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 82 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $1.02 $1.53 $2.55 0.00% 0.00% 2A Bracket - Support, Turbo Assembly 1575-N0101-01 1 Install Turbo Support Bracket, 2 Bolts OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 97 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $0.86 $1.29 $2.14 0.00% 0.00% 3A Vacuum Reservoir - Turbo Waste Gate 1599-N0101-01 1 Install Vacuum Reservoir, 2 Bolts and 1 Nut OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 90 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $0.93 $1.39 $2.32 0.00% 0.00% 4A Value - Thrust Control, Turbo Waste Gate Pneumatic Control 1599-N0101-02 1 Install Valve to Mount Bracket, No Additional Fastener OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 240 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $0.35 $0.52 $0.87 0.00% 0.00% 5A Tube Assembly - Turbo Waste Gate Pneumatic Control 1570-N0101-03 1 Install Waste Gate Tubing, 6 Attachment Points OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 73 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $1.13 $1.70 $2.84 0.00% 0.00% 6A Cooler Assembly - Charged Air 1505-N0101-01 1

Install Vehicle H/W for Charged Air Cooler and Charged Air Cooler.

OEM Assembly, Mark-up 

Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 49 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $1.71 $2.57 $4.29 0.00% 0.00% 

7A Tube Ass'y w. Vehicle Tie Down Canister, Air Cooler Inlet 1570-N0101-20/21/22 1 Install Tube Assembly, Turbo Assembly to Charged Air Cooler OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 75 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $1.11 $1.67 $2.78 0.00% 0.00% 8A Tube Ass'y w. Vehicle Tie Down Canister, Air Cooler Outlet 1570-N0101-30 1 Install Tube Assembly, Charged Air Cooler to Coupler/ETB bypass OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 61 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $1.37 $2.05 $3.42 0.00% 0.00% 9A Tube - Elbow, Upper to Charged Air Coupler By- Pass 1570-N0101-40 1

Make Connection Between Charged Air Outlet Tube and Electronic Throttle Body Inlet Tube.

OEM Assembly, Mark-up 

Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 189 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $0.44 $0.66 $1.10 0.00% 0.00% 

10A

Tube: Coupler Y Branch to By-Pass/Elbow Coupler By-Pass to Throttle Body/Elbow Coupler By-Pass to Throttle Body/Tube - Flex Elbow, Silencer to Environment

1570-N0101-41/42/43/44 1

Make Connection to Throttle 

Body and Snap in Bypass Tube to Vehicle Body

OEM Assembly, Mark-up 

Applied @ Bottom. Not Applicable General Assembly-OEM Vehicle Operations, OEM 92 1 1 1 0.000 $0.00 $83.31 $125.21 $125.21 $0.00 $0.90 $1.36 $2.26 0.00% 0.00% 

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

1A Turbo Charging Assembly 1501-N0101-01 1 SAC 

2A Bracket - Support, Turbo Assembly 1575-N0101-01 1 SAC 3A Vacuum Reservoir - Turbo Waste Gate 1599-N0101-01 1 SAC 4A Value - Thrust Control, Turbo Waste Gate Pneumatic Control 1599-N0101-02 1 SAC 5A Tube Assembly - Turbo Waste Gate Pneumatic Control 1570-N0101-03 1 SAC 6A Cooler Assembly - Charged Air 1505-N0101-01 1 SAC 7A Tube Ass'y w. Vehicle Tie Down Canister, Air Cooler Inlet 1570-N0101-20/21/22 1 SAC 8A Tube Ass'y w. Vehicle Tie Down Canister, Air Cooler Outlet 1570-N0101-30 1 SAC 9A Tube - Elbow, Upper to Charged Air Coupler By- Pass 1570-N0101-40 1 SAC 

10A

Tube: Coupler Y Branch to By-Pass/Elbow Coupler By-Pass to Throttle Body/Elbow Coupler By-Pass to Throttle Body/Tube - Flex Elbow, Silencer to Environment

1570-N0101-41/42/43/44 1 SAC 

11A Nut - Exhaust Manifold to Turbo 1280-N0101-07 4 S 12A Bolt - Bracket Support, Turbo Assembly 1580-N0101-03 1 S 13A Bolt - Bracket Support, Turbo Assembly 1580-N0101-04 1 S 14A Bolt - Pressure Reservoir, Turbo Waste Gate 1580-N0101-05 2 S 15A Nut - Pressure Reservoir, Turbo Waste Gate 1580-N0101-06 1 S 16A Bolt - Tube, Charge Air Cooler to Vehicle 1580-N0101-09 2 Hardware Not Available S 17A Internal Threaded Part ( Vehicle H/W) NA 2 Hardware Not Available S 18A Isolators Veh. Mnt. Charged Air Cooler NA 2 S 19A Bolt - Tube Ass'y w. Vehicle Canister Tie Down 

....

NA 1 Hardware Not Available S 

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

"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.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for 

both Technology Packages)

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 APpendix G.1-15, 15 of 16
Engine Assembly 1500 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Engine And Vehicle Assembly Part Number: 1500-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) 

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for 

both Technology Packages)

20A Internal Threaded Part ( Vehicle H/W Inlet (1 pc) & Outlet (2 pcs) Air Tube Canister Tie Down) NA 3 Hardware Not Available S 21A Bolt - Tube Charged Air Cooler Outlet NA 2 Hardware Not Available S 22A Screw Tube Intake Manifold to Attachment NA 1 Hardware Not Available S 

Material Labor Burden TMC Scrap SG&A 

T1 or OEM Total Manufacturing Cost: $221.21 $9.81 $14.75 $245.77 $0.00 $0.00 

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

(SAC) &T1 or OEM Mark-Up Values: (220.07) ----- ----- ----- $0.00 $0.00 

Base Cost Impact to Vehicle: $1.14 $9.81 $14.75 $25.70 $0.00 $0.00 

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

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 57447 

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 #

Pads 

Pallet/Ra

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

Packaging Cost Total: $0.000

 PACKAGING CALCULATIONS: No Packaging Considerations Required. Packaging Costs for fasteners (bolts, nuts, etc.) is captured in the piece costs.

File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3 APpendix G.1-15, 16 of 16
Appendix G.1 - Subsystem 17

Breather Subsystem

 Case Study #0101

MAQS Worksheets

File:Breather Subsystem 17 040209.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-17, 1 of 2
Oil-Air Separator 1702 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Oil/Air Separator Part Number: 1702-N0101-00 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

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

1A Oil/Air Separator 1702-N0101-00 1 Final Assembly of PCV system to cover. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 257 1 1 3 0.000 $0.00 $35.51 $15.00 $45.00 $0.00 $0.14 $0.18 $0.31 0.00% 0

0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 

Purchase Part - High Impact Item (Full Cost Mapping)

1A

Valve - Non Return Intake Hose & Manifold Side

1702-N0101-01/41-01 2 Injection Mold Flap with overmold Hinge T2/T3 Inject. Mold, MSMC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 720 1 1 1 0.005 $1.54 $43.52 $100.01 $100.01 $0.01 $0.06 $0.14 $0.21 0.50% 6

1B

Valve - Non Return Intake Hose & Manifold Side

1702-N0101-01/41-02 2 Two Shot Overmold T2/T3 Inject. Mold, MSMC Thermoset-NBR Mold/Cast/Sinter Operator Inject. Mold, SMS 800 0 1 1 0.002 $1.27 $43.52 $100.01 $100.01 $0.00 $0.00 $0.13 $0.13 0.50% 6

2A Separator - Cyclone 1702-N0101-10 1

Injection Mold (Additional Plastic added to Mini Cover over GEMA cover)

T2/T3 Inject. Mold, MSMC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS 545 0 1 1 0.818 $1.54 $43.52 $150.01 $150.01 $1.26 $0.00 $0.28 $1.53 0.50% 6

3A Valve - Pressure Control 1702-N0101-20 1 Nylon Injection Mold T2/T3 Inject. Mold, MSMC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 391 1 1 1 0.005 $1.54 $43.52 $100.01 $100.01 $0.01 $0.11 $0.26 $0.37 0.50% 63B Valve - Pressure Control 1702-N0101-20 1 Two Shot Overmold T2/T3 Inject. Mold, MSMC Thermoset-NBR Mold/Cast/Sinter Operator Inject. Mold, SMS 389 0 1 1 0.002 $1.27 $43.52 $100.01 $100.01 $0.00 $0.00 $0.26 $0.26 0.50% 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 

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

1A Hinge Flow control flap 1702-N0101-80 2 S 

0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $1.35 $0.37 $1.49 $3.21 $0.01 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.02 

Base Cost Impact to Vehicle: $1.35 $0.37 $1.49 $3.21 $0.03 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

 PACKAGING CALCULATIONS: No Packaging Impact

"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.

Full Quote Modification Differential Quote (Quote Summary includes 

File:Breather Subsystem 17 040209.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-17, 2 of 2
Appendix G.1 - Subsystem 60

Engine Management, Engine 

Electronic, and Electrical 

Subsystems

 Case Study #0101

MAQS Worksheets

File:Electrical Subsystem 6000 040209.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-60, 1 of 5
PCM HW 6002A Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Power Train Control Module (PCM) Assembly - Hardware Part Number: 0602-N0101-01 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

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

1A Power Train Control Module (PCM) Assembly - Hardware 0602-N0101-01 1

The PCM H/W is carry over 

except for the PFI drivers. GDI drivers use a 75-80VDC Boost Circuit and 25A Peak/Hold Drivers. The turbo is just another lowside driver really no cost. 

S 

0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $40.00 $0.00 $0.00 $40.00 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

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

Base Cost Impact to Vehicle: $40.00 $0.00 $0.00 $40.00 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: Packaging Type: NAPart Size:Parts/Layer:Number of Layers:

"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.

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

File:Electrical Subsystem 6000 040209.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-60, 2 of 5
PCM SW 6002B Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Power Train Control Module (PCM) Assembly - Software Part Number: 6002-N0101-50 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

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

1A Power Train Control Module (PCM) Assembly - Software 6002-N0101-50 1

• Control system is much more complicated in order to control injection timing, split injections, fuel rail pressure, electric water pump, electric thermostat, etc.

S 

0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $0.00 $0.00 $0.00 $0.00 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

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

Base Cost Impact to Vehicle: $0.00 $0.00 $0.00 $0.00 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

 PACKAGING CALCULATIONS: Packaging Type: NAPart Size:Parts/Layer:Number of Layers:

"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.

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

Per discussion with Brian Nelson, Software will be covered by indirect cost multiplier.5/20/09

File:Electrical Subsystem 6000 040209.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-60, 3 of 5
Electrical 6003 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets) Part Number: 6003-N0101-01/30 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)Purchase Part - Commodity ( Value taken from Purchase Part Database)

1A Wire Turbo Connector 0603-N0101-30 2 ($0.50/Wire Circuit) S 

2A Wire Coolant Aux Pump 0603-N0101-30 3 ($0.50/Wire Circuit) S 3A Clip Harness Retention 2 S 4A Wire Waste Gate Sol 0603-N0101-30 2 ($0.50/Wire Circuit) S 5A Wire Charge Air Temp 0603-N0101-30 4 ($0.50/Wire Circuit) S 6A Clip Harness Retention 1 S 7A Edge Biter Harness Retention 3 S 8A Wire HP Fuel Pump Control 2 ($0.50/Wire Circuit) S 9A Wire Fuel Pressure Sensor 0603-N0101-30 3 ($0.50/Wire Circuit) S 

10A Ignition Coil Assembly - Single Spark 0603-N0101-01 4 S 

0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $12.13 $0.00 $0.00 $12.13 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

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

Base Cost Impact to Vehicle: $12.13 $0.00 $0.00 $12.13 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: Negligible Change to Packaging

"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.

Full Quote Modification Differential Quote (Quote Summary includes 

File:Electrical Subsystem 6000 040209.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-60, 4 of 5
Engine Assembly 6000 Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets) Part Number: 6003-N0101-01-50 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

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

Additional Electrical Connections due to Turbo & DI Adds NA 1 Install Connectors, Secure Wiring OEM Engine Assembly Not Applicable General Assembly-OEM Engine Assembly, OEM 52 1 1 1 0.000 $0.00 $83.31 $150.21 $150.21 $0.00 $1.60 $2.88 $4.48 0.00% 0

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

1A Power Train Control Module (PCM) Assembly - Hardware 0602-N0101-01 1 SAC 

2A Power Train Control Module (PCM) Assembly - Software 6002-N0101-50 1 SAC 3A

Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)

0603-N0101-01/30 1 SAC 

4A 5A 6A 7A 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $52.13 $1.60 $2.88 $56.61 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

(SAC) &T1 or OEM Mark-Up Values: (52.13) ----- ----- ----- $0.00 

Base Cost Impact to Vehicle: $0.00 $1.60 $2.88 $4.48 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

9,574

1047

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

 PACKAGING CALCULATIONS: Negligible Change to Packaging

"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.

Full Quote Modification Differential Quote (Quote Summary includes 

File:Electrical Subsystem 6000 040209.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-60, 5 of 5
Appendix G.1 - Subsystem 70

Accessory Subsystem

 Case Study #0101

MAQS Worksheets

File:70 Accessory System 040209.xlsEPA Contract:EP-C-07-069 WA1-3 Appendix G.1-70, 1 of 4
Vacuum Pump Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Vacuum Pump Assembly Part Number: 7004-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

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

1A Vacuum Pump Assembly 7004-N0101-01 1 Final Assembly & Test Vacuum Pump S Not Applicable General Assembly Mech. Assembly, MC 240 3 0.000 $0.00 $35.51 $125.19 $0.00 $0.44 $0.52 $0.97 0.00% 0.00% 0.00% 0.00% 01B Base Vac Pump Rotor Support 7004-N0101-01-07-01 1 Subassembly Exhaust and Oil Vent Valve S Not Applicable General Assembly Mech. Assembly, MC 240 1 0.000 $0.00 $35.51 $125.19 $0.00 $0.15 $0.52 $0.67 0.00% 0.00% 0.00% 0.00% 0

Purchase Part - High Impact Item (Full Cost Mapping)

1A Base Vac Pump rotor support Casting 7004-N0101-01-07-01-02 1 Machine Casting S Not Applicable Mold/Cast/Sinter Operator Diecast, LMC 257 1 0.000 $0.00 $43.52 $100.05 $0.00 $0.17 $0.39 $0.56 0.30% 6.00% 4.00% 0.00% 101B Base Vac Pump rotor support Casting 7004-N0101-01-07-01-02-1 1 Casting S Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC 183 0.5 0.542 $1.10 $43.52 $100.05 $0.60 $0.12 $0.55 $1.26 0.30% 6.00% 4.00% 0.00% 102A Plate Oil vent relief 7004-N0101-01-07-01-04 1 Stamping & Heat Treat S SPR-Steel, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 720 0.25 0.005 $0.65 $42.18 $100.10 $0.00 $0.01 $0.14 $0.16 0.30% 6.00% 4.00% 0.00% 103A Plate retainer/limiter - Oil vent relief 7004-N0101-01-07-01-05 1 Stamping & Plating S LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 720 0.25 0.008 $0.45 $42.18 $100.10 $0.00 $0.01 $0.14 $0.16 0.30% 6.00% 4.00% 0.00% 104A Rotor Vac Pump 7004-N0101-01-08 1 Induction Harden S Not Applicable Lathe/Turning Operator CNC Turning, MHC 600 0.15 0.000 $0.00 $37.60 $125.00 $0.00 $0.01 $0.21 $0.22 0.30% 6.00% 4.00% 0.00% 104B Rotor Vac Pump 7004-N0101-01-08 1 Machine for Critical Tol. S Not Applicable Lathe/Turning Operator CNC Turning, MHC 109 0.85 0.000 $0.00 $37.60 $125.00 $0.00 $0.29 $1.15 $1.44 0.30% 6.00% 4.00% 0.00% 10

4C Rotor Vac Pump raw part 7004-N0101-01-08-1-1 1 PM Sinter S PM-SMF-FN0205 Mold/Cast/Sinter Operator Powder Metal, MHC 240 0.5 0.631 $2.00 $43.52 $150.14 $1.26 $0.09 $0.63 $1.98 0.30% 6.00% 4.00% 0.00% 10

5A Adapter Rotor Drive 7004-N0101-01-09 1 PM Sinter S PM-SMF-FC0208 Mold/Cast/Sinter Operator Powder Metal, LMC 360 0.5 0.139 $1.00 $43.52 $100.14 $0.14 $0.06 $0.28 $0.48 0.30% 6.00% 4.00% 0.00% 106A Retainer Rotor drive adapter 7004-N0101-01-10 1 Stamp & Plate S LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 1200 0.25 0.001 $0.45 $42.18 $100.10 $0.00 $0.01 $0.08 $0.09 0.30% 6.00% 4.00% 0.00% 107A Vane Vacuum Pump 7004-N0101-01-05 1 Form Edges and Plate S Not Applicable Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 720 0.25 0.000 $0.00 $42.18 $100.10 $0.00 $0.01 $0.14 $0.15 0.30% 6.00% 4.00% 0.00% 107B Vane Vacuum Pump 7004-N0101-01-05-01 1 Stamp Out Form S LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 1200 0.25 0.167 $0.45 $42.18 $100.10 $0.08 $0.01 $0.08 $0.17 0.30% 6.00% 4.00% 0.00% 108A Seal Pump Vane to wall 7004-N0101-01-06 2 PM Sinter S Not Applicable Mold/Cast/Sinter Operator Powder Metal, LMC 600 0.25 0.000 $0.00 $43.52 $100.14 $0.00 $0.02 $0.17 $0.19 0.30% 6.00% 4.00% 0.00% 108B Seal Pump Vane to wall 7004-N0101-01-06-01 2 PM Sinter S PM-SMF-FN0205 Mold/Cast/Sinter Operator Powder Metal, LMC 480 0.25 0.026 $2.00 $43.52 $100.14 $0.05 $0.02 $0.21 $0.28 0.30% 6.00% 4.00% 0.00% 109A Cover Vacuum Pump 7004-N0101-01-01 1 Stamp & Plate S LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC 180 1 1.070 $0.45 $42.18 $100.10 $0.48 $0.23 $0.56 $1.27 0.30% 6.00% 4.00% 0.00% 10

10A Fitting Vac Outlet Port 7004-N0101-01-03 1 Assemble Outlet Fitting S Purchased Parts General Assembly Mech. Assembly, LC 450 1 0.265 $1.00 $35.51 $100.19 $0.27 $0.08 $0.22 $0.57 0.30% 6.00% 4.00% 0.00% 1010B Fitting Vac Outlet Port 7004-N0101-01-03-01 1 Injection Mold Housing S Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 480 0.25 0.014 $1.54 $43.52 $100.01 $0.02 $0.02 $0.21 $0.25 0.30% 6.00% 4.00% 0.00% 10

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

1A Fitting Clean Air Inlet 7004-N0101-01-07-01-03 1 S 2A Rivet solid, Oil vent plates 7004-N0101-01-07-01-06 1 S 3A Gasket Vac Pump Cover (SBR) 7004-N0101-01-02 1 S 4A Bolt - Vacuum Pump Housing 7080-N0101-10 4 S 5A Sleeve Anti Crush 7004-N0101-01-03-02 1 B10A 5B Check Valve 7004-N0101-01-03-03 1 B10A 

5C Spring Check Valve 7004-N0101-01-03-04 1 B10A 5D Seat check valve spring 7004-N0101-01-03-05 1 B10A 

5E O-Ring - Vac fitting 7004-N0101-01-04 1 B10A 6A Bolt - Vac Fitting 7080-N0101-10 1 S 

T1 or OEM Total Manufacturing Cost: $3.31 $1.81 $6.56 $11.69 $0.03 $0.58 $0.39 $0.00 $

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15

T1 or OEM Mark-Up Values: ----- ----- ----- ----- $0.06 $0.82 $0.76 $0.32 $

Base Cost Impact to Vehicle: $3.31 $1.81 $6.56 $11.69 $0.09 $1.41 $1.15 $0.32 $

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

File:70 Accessory System 040209.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-70, 2 of 4
Vacuum Pump Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Vacuum Pump Assembly Part Number: 7004-N0101-01 Weekly Component Volume:

Component Quote Level: Full Quote X Modification Quote Estimated Product Life:

Reference # Part Description Part Number

QTY Per Assembly Primary Process Description

OEM or Supplier Material Specification Labor Classification Burden Classification

Finished Pieces Per Hour

Number of Operators

Material Usage "lbs" Material Cost $/lb (DB) Labor Rate $/Hour (DB) Burden Rate $/Hour (DB) Material Cost Labor/ Part Burden/ Part

Total 1 = 

Material + Labor + Burden End Item Scrap Rate SG&A Rate Profit Rate ED&T/ R&D Rate T

M

R

10

9,574

47

450,000

1

450,000

MARK-UP COSTS

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

Packaging Calculations 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

Su

Cu

a

t

In

Req

ts 

Rack/Pallet Investment Amortization: $0.018 $35,461 0.00% 2,250,000 60 5.00% $200 177 432 

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

O

Pal

Expendable Packaging in Piece Cost: $0.08 $1.00 9 $3.00 8 $0.00 0 $0.00 0 $0.00 

Packaging Cost Total: $0.094

File:70 Accessory System 040209.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-70, 3 of 4
Engine Assembly Manufacturing Assumption and Quote Summary 

Technology Level: Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle Class OEM Operating Pattern (Weeks/Year): 

Vehicle Class: Compact/Economy 2-4 Passenger Annual Engine Volume (CPV): 

Study Case#: N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class ) Components per Engine: 

System Description: 2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI Turbo Annual Component Volume: 

Component Description: Engine Assembly of Accessory Subsystem Components to Engine Part Number: 7000 Weekly Component Volume: 

Component Quote Level: Estimated Product Life:

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) S

R

(

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

Vacuum Pump Assembly 7004-N0101-01 1 Mount Vacuum Pump to Head OEM Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly-OEM Engine Assembly, OEM 113 1 1 1 0.000 $0.00 $83.31 $150.21 $150.21 $0.00 $0.74 $1.34 $2.08 0.00% 0

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

Bolt - Vacuum Pump 7080-N0101-01 2 S 

Seal - Vacuum Pump to Head 7004-N0101-01-11 1 S 

0 0 0 0 0 0 0 0 0 

Material Labor Burden TMC Scrap S

T1 or OEM Total Manufacturing Cost: $0.13 $0.74 $1.34 $2.20 $0.00 

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0

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

Base Cost Impact to Vehicle: $0.13 $0.74 $1.34 $2.20 $0.00 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

q

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 4,500,000 60 5.00% $0 5

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

O

Pa

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

Packaging Cost Total: $0.000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS 

9,574

1047

450,000

1

450,000

 PACKAGING CALCULATIONS: Packaging for fasteners covered in piece price.

"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.

Full Quote Modification Quote Differential Quote (Quote Summary includes 

File:70 Accessory System 040209.xlsEPA Contract: EP-C-07-069 WA1-3 Appendix G.1-70, 4 of 4