Appendix G.1 - Subsystem 03Crank Drive SubsystemCase Study #0101MAQS WorksheetsFile:Crank Drives 03, 032509.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-03, 1 of 7Crankshaft 0301Manufacturing Assumption and Quote SummaryAPPENDIX G.1-03 (1of4)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Shaft - CrankPart Number:0301-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Shaft - Crank (Mini Cooper) 0301-N0101-011Considered for Weight DeltaOnly, Assume Fabrication andMachining times a washbetween Mini and ChryslerCrankshaftOEM MA-Steel-MnVS, Bar Not Applicable Not Applicable116 025.28$0.73 $0.00 $0.00 $18.45$0.00 $0.00$18.450.00% 0.00% 0.00% 0.00%0.00% $0.00 $18.45 $18.45Shaft - Crank ( Chrysler Gema) 0301-B0101-011"See Note Above" OEM MA-Steel-MnVS, Bar Not ApplicableNot Applicable116 0-39.81$0.73 $0.00 $0.00 -$29.06$0.00 $0.00-$29.060.00% 0.00% 0.00% 0.00%0.00% $0.00 -$29.06 -$29.06Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net, PIAPurchase PriceNet, End Item0$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotal Mark-up-$10.61T1 or OEM Total Manufacturing Cost:-$10.61 $0.00 $0.00 -$10.61 $0.00 $0.00 $0.00 $0.00 $0.00 -$10.61T1 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 -$1.67Base Cost Impact to Vehicle:-$10.61 $0.00 $0.00 -$10.61 -$0.07 -$0.74 -$0.85 $0.00 -$1.67 -$12.27 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:-$12.27Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customer andIn-transitInventoryRequirements(Weeks)Supplier,Customer and Intransit InventoryRequirements(Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3 PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BTBD109,57447450,0001450,000PACKAGING CALCULATIONS:Assume No Impact to Packaging"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-03, 2 of 7Form Author: G. Kolwich(248)373-6000 Ext. 2411Con.Rod0303Manufacturing Assumption and Quote SummaryAPPENDIX G.1-03, (2of4)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Rod Subassembly - ConnectingPart Number:0303-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Rod Subassembly - Connecting 0303-N0101-01-011Weight Cost Differential Only,Fabrication and Machining areequivalent between Mini &Chrysler Con. Rods.Mini-Cooper RodL/R = 138.5/(85.9/2) = 3.22S MA-Steel-C70S6, Bar Not Applicable Not Applicable450 00.964$0.70 $0.00 $0.00 $0.67$0.00 $0.00$0.670.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.67 $0.671B Rod Subassembly - Connecting 0303-N0101-011Install Bushing & Size S Not Applicable General Assembly Mech. Assembly, MC450 00.000$0.00 $35.51 $125.19$0.00 $0.00$0.28 $0.280.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.28 $0.282A Rod Subassembly - Connecting 0303-B0101-01&021Chrysler GEMA Rod WeightMA-Steel-C70S6, Bar Not Applicable Not Applicable450 0-0.979$0.70 $0.00 $0.00 -$0.69$0.00 $0.00-$0.690.00% 0.00% 0.00% 0.00%0.00% $0.00 -$0.69 -$0.692B Rod Subassembly - Connecting 0303-B0101-01&02-M1Additional Material Requiredto Equalize L/R RatioGEMA Prod. L/R = 2.96,R = 97/2 = 48.5 & L=143.75mmAssuming Mini L/R (3.22).Hold stroke constantL=3.22*48.5= 156.17mmTherefore rod length wouldincrease by 12.42mmMA-Steel-C70S6, Bar Not Applicable Not Applicable450 0-0.032$0.70 $0.00 $0.00 -$0.02$0.00 $0.00-$0.020.00% 0.00% 0.00% 0.00%0.00% $0.00 -$0.02 -$0.02Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccount CostPurchasePrice/ UnitPurchase PriceNet, PIAPurchase PriceNet, End ItemBushing - Connecting Rod 0303-N0101-021Aluminum Bronze S$0.00$0.33$0.00 $0.330(Blank 40x30x0.5 mmm)$0.00$0.00$0.00 $0.000Meanρ= 0.270$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotal Mark-up$0.58T1 or OEM Total Manufacturing Cost:$0.30 $0.00 $0.28 $0.58 $0.00 $0.00 $0.00 $0.00 $0.00 $0.58T1 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 $0.09Base Cost Impact to Vehicle:$0.30 $0.00 $0.28 $0.58 $0.00 $0.04 $0.03 $0.01 $0.09 $0.67 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$0.67TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BNA1038,29847450,00041,800,000"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-03, 3 of 7Form Author: G. Kolwich(248)373-6000 Ext. 2411Con.Rod0303Manufacturing Assumption and Quote SummaryAPPENDIX G.1-03, (2of4)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Rod Subassembly - ConnectingPart Number:0303-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BNA1038,29847450,00041,800,000Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customer andIn-transitInventoryRequirements(Weeks)Supplier,Customer andIn-transitInventoryRequirements(Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%18,000,000 605.00%$022978716229787Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3 PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$1.00 0 $3.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000PACKAGING CALCULATIONS:No Change Required For Packaging.File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-03, 4 of 7Form Author: G. Kolwich(248)373-6000 Ext. 2411Piston0304Manufacturing Assumption and Quote SummaryAPPENDIX G.1-03, (3of4)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Piston - Engine, MachinedPart Number:0304-N0101-01Weekly Component Volume: Packaging Specification:Component Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Piston - Engine, Cast (Mini Cooper) 0304-N0101-01-011Consider weight, material andscrap (+5%) differences in casthypereutectic material.T2/T3 Internal Supplier Aluminum-B390, Cast Mold/Cast/Sinter Operator Diecast, LMC517 3 3 10.651$1.20 $43.52 $100.05 $300.15 $0.78 $0.25 $0.58 $1.61 5.00% 0.00% 0.00% 0.00% 5.00% $0.08 $1.70 $1.701B Piston - Engine, Machined (Mini Cooper) 0304-N0101-01-011T6 Heat Treat T2/T3 Internal Supplier Not Applicable Heat Treat Operator Heat Treat, SMS, MHC442 2 4 10.000$0.00 $46.52 $100.00 $400.00$0.00$0.21 $0.90 $1.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.12 $1.121C Piston - Engine, Machined (Mini Cooper) 0304-N0101-011Machining (5% Premium onTime Accounted for in rate)T2/T3 Internal Supplier Not Applicable CNC OperatorRot./Lin. Trans. MachiningLine, TP, PREM.480 1 2 1.050.000$0.00 $35.70 $260.00 $546.00$0.00$0.07 $1.14 $1.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.21 $1.212A Piston - Engine, Machined (Chrysler GEMA)) 0304-B0101-01-011Consider weight and materialdifferences only as cost factorin 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% 0.00% 0.00% 0.00% $0.00 -$1.71 -$1.712B Piston - Engine, Machined (Chrysler GEMA)) 0304-B0101-01-011T5 Heat Treat T2/T3 Internal Supplier Not Applicable Heat Treat Operator Heat Treat, SMS, LMC-420 1 2 10.000$0.00 $46.52 $50.00 $100.00$0.00-$0.11 -$0.24 -$0.35 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$0.35 -$0.352C Piston - Engine, Machined (Chrysler GEMA)) 0304-B0101-01-011Machining T2/T3 Internal Supplier Not Applicable CNC OperatorRot./Lin. Trans. MachiningLine, TP-480 1 2 10.000$0.00 $35.70 $250.00 $500.00$0.00-$0.07 -$1.04 -$1.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$1.12 -$1.120##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net, PIAPurchase PriceNet, End Item0$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotal Mark-up$0.85T1 or OEM Total Manufacturing Cost:-$0.09 $0.10 $0.76 $0.77 $0.08 $0.00 $0.00 $0.00 $0.08 $0.85T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.06 $0.05 $0.02 $0.13Base Cost Impact to Vehicle:-$0.09 $0.10 $0.76 $0.77 $0.08 $0.06 $0.05 $0.02 $0.21 $0.98$0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$0.98North AmericaNorth AmericaFOB Ship PointTOTAL COSTS47450,00041,800,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES38,29810MARK-UP COSTSTOOLING & INVESTMENTNA"S"=Indicates Component is Supplied directly to T1or OEM for Final orSub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplieddirectly to T1 or OEM for Final or Sub-Assembly. In addition componentmaterial cost is accounted for in T1 quote sheet.Thus component costwill only be included for Mark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in byT2/T3 Supplier for Subassembly.31Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)Note, both the Mini and Chrysler GEMA pistons haveanodized top ringgroove and a dry-film skirt coating.File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-03, 5 of 7Form Author: G. Kolwich(248)373-6000 Ext. 2411Piston0304Manufacturing Assumption and Quote SummaryAPPENDIX G.1-03, (3of4)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Piston - Engine, MachinedPart Number:0304-N0101-01Weekly Component Volume: Packaging Specification:Component Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "North AmericaNorth AmericaFOB Ship PointTOTAL COSTS47450,00041,800,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES38,29810MARK-UP COSTSTOOLING & INVESTMENTNAFull QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)Cost perPieceTotalAmountLumpSumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%18,000,000 605.00%$025016229787Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000PACKAGING CALCULATIONS:Packaging Type:NO CHANGE TO PACKAGINGPart Size:Parts/Layer:Number of Layers:File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-03, 6 of 7Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 0300Manufacturing Assumption and Quote SummaryAPPENDIX G.1-03 (4of4)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:OEM Engine AssemblySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Engine Assembly of Crank Drive Subsystem ComponentsPart Number:0300-N0101-01Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)0##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Shaft - Crank 0301-N0101-011(OEM Mark-up included in Crankshaft Worksheet)$0.00$0.00$0.00 $0.002A Rod Subassembly - Connecting 0303-N0101-014SAC$2.66$0.67$0.00 $2.663A Piston - Engine, Machined 0304-N0101-014SAC$3.92$0.98$0.00 $3.924A Ring/Clip - Piston Pin Retainer 0304-N0101-028S$0.00$0.03$0.00 $0.245A Pin- Piston 0304-N0101-034GEMA 15Cr3(SAE5015) CaseHardenedMini 31CrMoV9 NitridedS$0.00$0.24$0.00 $0.966A Compression Ring - Piston, Top 0304-N0101-044S$0.00$0.35$0.00 $1.427A Compression Ring - Piston, 2nd 0304-N0101-054S$0.00$0.17$0.00 $0.668A Spacer/Expander/Coil Spring - Oil Ring, Piston 0304-N0101-074S$0.00$0.17$0.00 $0.689A Rail(s) - Oil Ring, Piston 0304-N0101-084S$0.00$0.06$0.00 $0.2210A Bearing - Connecting Rod to Crank Shaft 0390-N0101-018AlSn20Mn Base, AlSn10NiTurbo DIS$0.00$0.19$0.00 $1.510$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$12.27T1 or OEM Total Manufacturing Cost:$12.27 $0.00 $0.00 $12.27 $0.00 $0.00 $0.00 $0.00 $0.00 $12.27T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:(6.58)----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$5.69 $0.00 $0.00 $5.69 $0.00 $0.00 $0.00 $0.00 $0.00 $5.69 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$5.69Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$02501657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:Packaging Type:No Changes Required toPackagingPart Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)No impact to engine assembly. Assume wrist pinretaining clip labor/burden add would be offset bylabor/burden press fit pin design.File:Crank Drives 03, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-03, 7 of 7Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 04Counter Balance SubsystemCase Study #0101MAQS WorksheetsFile:Counter Balance, 031908.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-04, 1 of 4Balance Shaft Subassembly 0401Manufacturing Assumption and Quote SummaryAPPENDIX G.1-04, (1of2)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hpAnnual Component Volume: Shipping Method:Component Description:Balance Shaft Assembly ( Part of Oil Pump Assembly)Part Number:0401-B0101-01Weekly Component Volume: Packaging Specification:Returnable DunnageComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Mutiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Upper and Lower Housing assembly Machining 0401-B0101-11-011Assemble upper and lowerhousings, machine bearings.T1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base240 2 1 80.000$0.00 $35.51 $15.00 $120.00$0.00$0.30 $0.50 $0.80 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.80 $0.802A Balance Shaft Long and Short 0401-B0101-06/072Press Gears onto balanceshafts. (1 of each shaft type)T1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base240 1 2 10.000$0.00 $35.51 $15.00 $30.00$0.00$0.15 $0.13 $0.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $0.553A Final Assembly of Balance Shaft Assembly 0401-B0101-011Assemble Shafts into Houisngand rundown fasteners.T1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base240 4 1 50.000$0.00 $35.51 $15.00 $75.00$0.00$0.59 $0.31 $0.90 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.90 $0.90Purchase Part - High Impact Item (Full Cost Mapping)1A Bottom Housing Casting 0401-B0101-03-1-11Casting T2/T3 Diecast, MSMC Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC112 1 1 12.351$1.10 $43.52 $100.05 $100.05 $2.59 $0.39 $0.89 $3.87 5.00% 6.50% 6.00% 1.00% 18.50% $0.72 $4.58 $4.581B Bottom Housing Casting 0401-B0101-03-11Machine Casting T2/T3 Diecast, MSMC Not Applicable CNCOperator CNC Machining, LMC115 1 1.5 10.000$0.00 $35.70 $25.00 $37.50$0.00$0.31 $0.33 $0.64 5.00% 6.50% 6.00% 1.00% 18.50% $0.12 $0.75$0.752A Top Housing Balance Shaft Casting 0401-B0101-08-1-11Casting T2/T3 Diecast, MSMC Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC111 1 1 12.609$1.10 $43.52 $100.05 $100.05 $2.87 $0.39 $0.90 $4.17 5.00% 6.50% 6.00% 1.00% 18.50% $0.77 $4.94 $4.942B Top Housing Balance Shaft 0401-B0101-08-11Machine Casting T2/T3 Diecast, MSMC Not Applicable CNCOperator CNC Machining, LMC114 1 2 10.000$0.00 $35.70 $25.00 $50.00$0.00$0.31 $0.44 $0.75 5.00% 6.50% 6.00% 1.00% 18.50% $0.14 $0.89$0.893A Balance Shaft Short Casting 0401-B0101-06-1-1-11Casting T2/T3 Diecast, MSMC Nodular Iron, Cast Mold/Cast/Sinter Operator Perm. Cast, LMC242 3 1 11.721$0.35 $43.52 $100.06 $100.06 $0.60 $0.54 $0.41 $1.56 5.00% 6.50% 6.00% 1.00% 18.50% $0.29 $1.84 $1.843B Balance Shaft Short Casting 0401-B0101-06-1-1-11Heat Treating T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC242 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.19 $0.41 $0.61 0.50% 6.50% 6.00% 1.00% 14.00% $0.08 $0.69$0.693C Balance Shaft Short Machined 0401-B0101-06-1-11Machine T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, HC113 0.5 1.5 10.000$0.00 $35.70 $75.00 $112.50$0.00$0.16 $1.00 $1.16 0.50% 6.50% 6.00% 1.00% 14.00% $0.16 $1.32$1.323D Balance Shaft Short Machined 0401-B0101-06-1-11Grind T2/T3 CNC Turning, MSMC Not Applicable CNC Operator Grinding, SMS, MHC132 0.5 1.25 10.000$0.00 $35.70 $65.00 $81.25$0.00$0.13 $0.61 $0.75 0.50% 6.50% 6.00% 1.00% 14.00% $0.10 $0.85$0.853E Balance Shaft Short Machined 0401-B0101-061Balance T2/T3 CNC Turning, MSMC Not Applicable CNC Operator Balancing, MLS, LMC120 0.5 1 10.000$0.00 $35.70 $25.00 $25.00$0.00$0.15 $0.21 $0.36 0.50% 6.50% 6.00% 1.00% 14.00% $0.05 $0.41$0.414A Balance Shaft Short Casting 0401-B0101-07-1-1-11Casting T2/T3 Diecast, MSMC Nodular Iron, Cast Mold/Cast/Sinter Operator Perm. Cast, LMC226 3 1 12.242$0.35 $43.52 $100.06 $100.06 $0.78 $0.58 $0.44 $1.80 5.00% 6.50% 6.00% 1.00% 18.50% $0.33 $2.14 $2.144B Balance Shaft Short Casting 0401-B0101-07-1-1-11Heat Treating T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC242 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.19 $0.41 $0.61 0.50% 6.50% 6.00% 1.00% 14.00% $0.08 $0.69$0.694C Balance Shaft Short Machined 0401-B0101-07-1-11Machine T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, HC114 0.5 2.25 10.000$0.00 $35.70 $75.00 $168.75$0.00$0.16 $1.48 $1.64 0.50% 6.50% 6.00% 1.00% 14.00% $0.23 $1.86$1.864D Balance Shaft Short Machined 0401-B0101-07-1-11Grind T2/T3 CNC Turning, MSMC Not Applicable CNC Operator Grinding, SMS, MHC142 0.5 1.3 10.000$0.00 $35.70 $65.00 $84.50$0.00$0.13 $0.60 $0.72 0.50% 6.50% 6.00% 1.00% 14.00% $0.10 $0.82$0.824E Balance Shaft Short Machined 0401-B0101-071Balance T2/T3 CNC Turning, MSMC Not Applicable CNC Operator Balancing, MLS, LMC120 0.5 1 10.000$0.00 $35.70 $25.00 $25.00$0.00$0.15 $0.21 $0.36 0.50% 6.50% 6.00% 1.00% 14.00% $0.05 $0.41$0.415A Gear Balance Shaft 0401-B0101-06-2-12Machine Blank & Hob Teeth(Same process for both Gears)T2/T3 CNC Turning, MSMC LC-Steel-1215, Bar CNC Operator Balancing, MLS, LMC235 2 4.5 10.000$0.62 $35.70 $25.00 $112.50$0.00$0.30 $0.48 $0.78 0.50% 6.50% 6.00% 1.00% 14.00% $0.11 $0.89$1.795B Gear Balance Shaft 0401-B0101-06-2-12Heat Treating T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC360 1 1 10.000$0.00 $46.52 $50.00 $50.00$0.00$0.13 $0.14 $0.27 0.50% 6.50% 6.00% 1.00% 14.00% $0.04 $0.31$0.61Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Dowel Upper to lower housing alignment 0401-B0101-042S$0.00$0.03$0.00 $0.052A Bearing Shell Balance Shaft 0401-B0101-054S$0.00$0.25$0.00 $1.003A Bolt Balance Shaft Housing 0401-B0101-096S$0.00$0.06$0.00 $0.364A Cap Shaft Close out 0401-B0101-102S$0.00$0.14$0.00 $0.280$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$28.54T1 or OEM Total Manufacturing Cost:$8.53 $5.83 $10.65 $25.01 $0.68 $1.37 $1.26 $0.21 $3.53 $28.54T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.14 $1.85 $1.71 $0.71 $4.42Base Cost Impact to Vehicle:$8.53 $5.83 $10.65 $25.01 $0.82 $3.22 $2.98 $0.92 $7.95 $32.96 $0 $0Packaging Cost:$0.05Net Cost Impact to Vehicle:$33.019,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENT"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)File:Counter Balance, 031908.xlsEPA Contract: EP-C-07-069 WA1-3APpendix, G.1-04, 2 of 4Form Author: G. Kolwich(248)373-6000 Ext. 2411Balance Shaft Subassembly 0401Manufacturing Assumption and Quote SummaryAPPENDIX G.1-04, (1of2)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hpAnnual Component Volume: Shipping Method:Component Description:Balance Shaft Assembly ( Part of Oil Pump Assembly)Part Number:0401-B0101-01Weekly Component Volume: Packaging Specification:Returnable DunnageComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Mutiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTFull QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.053 $105,0000.00%2,250,000 605.00%$420250175657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.053PACKAGING CALCULATIONS:Consider additional volume as result of BalanceShaft subassembly:Packaging Type: Option #2Part Size: 190x220 x120Parts/Layer: 5 x 5Number of Layers:7File:Counter Balance, 031908.xlsEPA Contract: EP-C-07-069 WA1-3APpendix, G.1-04, 3 of 4Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 04Manufacturing Assumption and Quote SummaryAPPENDIX G.1-04, (2of2)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:OEM Engine AssemblySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Engine Assembly of Balance Shaft AssemblyPart Number:Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Mutiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Mount Balance Shaft Assembly to Engine 0401-B0101-011Install Balance Shaft Assemblyto block, 4 Bolts.OEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Engine Assembly,OEM212 1 1 10.000$0.00 $83.31 $150.21 $150.21$0.00$0.39 $0.71 $1.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.10 $1.10Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Bolt - Balance Shaft Assembly Mount to Block PC 12.94(Packaging Included in Cost) S$0.00$0.46$0.00 $1.832ABalance Shaft Assembly ( Part of Oil PumpAssembly)0401-B0101-011SAC$33.01$33.01$0.00 $33.010$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$35.95T1 or OEM Total Manufacturing Cost:$34.84 $0.39 $0.71 $35.95 $0.00 $0.00 $0.00 $0.00 $0.00 $35.95T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:(33.01)----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$1.83 $0.39 $0.71 $2.93 $0.00 $0.00 $0.00 $0.00 $0.00 $2.93 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$2.93Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$02501657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.0009,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTPACKAGING CALCULATIONS:Packaging Type:Part Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)File:Counter Balance, 031908.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-04, 4 of 4Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 05Cylinder Block SubsystemCase Study #0101MAQS WorksheetsFile:Cylinder Block 05, 032509.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-05, 1 of 8Cylinder Block 0501Manufacturing Assumption and Quote SummaryAPPENDIX G.1-05, (1of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Cylinder Block Assembly - Machined w. Studs, Plugs,etc.Part Number:0501-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1ACylinder Block Subassembly - Machinedw/o Studs/Plugs, etc0501-N0101-01 (Mini Cooper)1Upper cylinder blockmachiningOEMNot ApplicableCNC Operator-OEM CNC Milling, LS, HC135 0.250.000$0.00 $68.07 $250.00$0.00$0.13 $1.86 $1.980.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.98 $1.981BCylinder Block Subassembly - Machinedw/o Studs/Plugs, etc0501-B0101-01 ( Chrysler GEMA)1Machining operation adds formounting balance shaftassembly.OEMNot ApplicableCNC Operator-OEM CNC Milling, LS, HC-288 0.250.000$0.00 $68.07 $250.00$0.00-$0.06 -$0.87 -$0.930.00% 0.00% 0.00% 0.00%0.00% $0.00 -$0.93 -$0.931CCylinder Block Subassembly - Cast0501-N0101-031Main Cooper Block minusliners =29.19Chrysler GEMA Block minusliners = (33.655 + 2.08)OEM Aluminum-A380, CastNot Applicable Not Applicable89 0-6.545$1.10 $0.00 $0.00 -$7.20$0.00 $0.00-$7.205.00% 0.00% 0.00% 0.00%5.00% -$0.36 -$7.56 -$7.560##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.00Purchase Part - High Impact Item (Full Cost Mapping)1ACylinder Liners - Cast Iron0501-N0101-044Mini Cooper Liners = 1.9lbs/liner, Chrysler GEMAEngine = 2.44lbs/linerOEMNodular Iron, Cast Not Applicable Not Applicable450 0-0.540$0.35 $0.00 $0.00 -$0.19$0.00 $0.00-$0.190.30% 6.00% 4.00% 0.00%10.30% -$0.02 -$0.21 -$0.830##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item0$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up-$7.34T1 or OEM Total Manufacturing Cost:-$7.96 $0.07 $0.99 -$6.90 -$0.36 -$0.05 -$0.03 $0.00 -$0.44-$7.34T1 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 -$1.15Base Cost Impact to Vehicle:-$7.96 $0.07 $0.99 -$6.90 -$0.41 -$0.56 -$0.62 $0.00 -$1.59-$8.49 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:-$8.49TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000NA9,57447North America450,000North America"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31Timing 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/BeadPlateNAAssume casting speed for Chryslerand Mini Cooper Block will beapproximately the same. Thus noadditional Labor or Burden costs wereaccounted for.Assume processing speed forChrysler and Mini Cooper linerswill be approximately the same.Thus no additional Labor orBurden costs were accountedfor.NAFile:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-05, 2 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Cylinder Block 0501Manufacturing Assumption and Quote SummaryAPPENDIX G.1-05, (1of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Cylinder Block Assembly - Machined w. Studs, Plugs,etc.Part Number:0501-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000NA9,57447North America450,000North AmericaPackaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000PACKAGING CALCULATIONS:Negligible Affect to PackagingFile:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-05, 3 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Bed Plate 0503Manufacturing Assumption and Quote SummaryAPPENDIX G.1-05, (2of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Bed Plate Assembly - Machined w. Studs, Plugs, etc.Part Number:0503-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)A1.1Bed Plate Subassembly - Cast0503-N0101-021Bed Plate casting OEMAluminum-A380,CastNot Applicable Not Applicable107 0-3.663$1.10 $0.00 $0.00 -$4.03$0.00 $0.00-$4.035.00% 0.00% 0.00% 0.00%5.00% -$0.20 -$4.23 -$4.23#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.00Purchase Part - High Impact Item (Full Cost Mapping)1A Bearing Cap - Bolt Through - Insert, Steel 0503-N0101-035Main Bearing Caps, Cast S Nodular Iron, CastNot Applicable Not Applicable554 0-0.190$0.35 $0.00 $0.00 -$0.07$0.00 $0.00-$0.075.00% 6.00% 4.00% 0.00%15.00% -$0.01 -$0.08 -$0.380#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.000#DIV/0! 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.30% 6.00% 4.00% 0.00%10.30% #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item0$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 $0.000$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 $0.00TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000NA9,57447North America450,000North America"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.Mini Cooper Bed Plate integrated Bearing Cap Weight = 18.01lbsChrysler Girdle has non integrated bearing capsWeight of Girdle =17.423+ Cover Contribution 0.75 -Oil FilterInlet 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% ofBedplate weight are for Bearing Caps, Thus the followingcalculations are made:Weight of Base Bed Plate Material = 79.2%x18.01 = 14.26 lbsWeight of Bearing Caps = 20.8%x18.01 = 3.75 lbsAssume casting speed forChrysler and Mini Cooper BedPlate will be approximately same.Thus no additional Labor orBurden costs were accountedfor.NAAssume casting speed forChrysler and Mini CooperBearing Caps will beapproximately the same. Thusno additional Labor or Burdencosts were accounted for.NAFile:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-05, 4 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Bed Plate 0503Manufacturing Assumption and Quote SummaryAPPENDIX G.1-05, (2of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Bed Plate Assembly - Machined w. Studs, Plugs, etc.Part Number:0503-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000NA9,57447North America450,000North America0$0.00$0.00$0.00 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up-$4.61T1 or OEM Total Manufacturing Cost:-$4.36 $0.00 $0.00 -$4.36 -$0.22 -$0.02 -$0.01 $0.00 -$0.25-$4.61T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.70% 7.00% 8.00% 0.00% 15.70%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- ------$0.03 -$0.32 -$0.37 $0.00 -$0.72Base Cost Impact to Vehicle:-$4.36 $0.00 $0.00 -$4.36 -$0.25 -$0.34 -$0.38 $0.00 -$0.98-$5.34 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:-$5.34Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$1.00 0 $3.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000Negligible Affect To Packaging31File:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-05, 5 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Piston Cooling 0504Manufacturing Assumption and Quote SummaryAPPENDIX G.1-05, (3of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Squirter - Oil, Piston Cooler & RetainerPart Number:0504-N0101-01/02Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)1A Bolt - Piston Cooler Valve/Retainer 0504-N0101-021Purchase Part Cost Est. Break OutS Purchased Parts General Assembly Mech. Assembly, LC206 0.50.350$1.00 $35.51 $100.19 $0.35 $0.09 $0.49 $0.920.30% 6.00% 4.00% 0.00%10.30% $0.10 $1.02 $1.022A Squirter - Oil, Piston Cooler 0504-N0101-011Purchase Part Cost Est. Break OutS Purchased Parts General Assembly Mech. Assembly, LC240 0.50.300$1.00 $35.51 $100.19 $0.30 $0.07 $0.42 $0.790.30% 6.00% 4.00% 0.00%10.30% $0.08 $0.87 $0.87Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End ItemMaterial Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$1.89T1 or OEM Total Manufacturing Cost:$0.65 $0.16 $0.90 $1.71 $0.01 $0.10 $0.07 $0.00 $0.18 $1.89T1 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 $0.19Base Cost Impact to Vehicle:$0.65 $0.16 $0.90 $1.71 $0.01 $0.22 $0.14 $0.00 $0.37 $2.09 $0 $0Packaging Cost:$0.01Net Cost Impact to Vehicle:$2.10Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%18,000,000 605.00%$04605006229787Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.01$0.00 0 $0.00 0 $2.50 2 $0.00 0 $0.00 0Packaging Cost Total:$0.0101038,29847450,00041,800,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BCardboard BoxesGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENT31PACKAGING CALCULAIONS:Use $0.005 additional cost for bothsquirter and bolt/check valve.Assume 250 parts/box, $2.50/Box,File:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-05, 6 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Bearing Elements 0590Manufacturing Assumption and Quote SummaryAPPENDIX G.1-05, (4of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Bearings & Thrust Shims - Crankshaft,Part Number:0590-N0101-01/02/03Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccount CostPurchasePrice/ UnitPurchasePrice Net, PIAPurchasePrice Net, EndItemBearing - Crankshaft, 1/2 Bearing (Top)0590-N0101-015S$0.00$0.19$0.00 $0.97Bearing/Shim - Crankshaft Thrust0590-N0101-022S$0.00$0.12$0.00 $0.24Bearing - Crankshaft, 1/2 Bearing (Bottom)0590-N0101-035S$0.00$0.18$0.00 $0.920$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotal Mark-up$2.13T1 or OEM Total Manufacturing Cost:$2.13 $0.00 $0.00 $2.13 $0.00 $0.00 $0.00 $0.00 $0.00 $2.13T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$2.13 $0.00 $0.00 $2.13 $0.00 $0.00 $0.00 $0.00 $0.00 $2.13 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$2.13Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customer andIn-transitInventoryRequirements(Weeks)Supplier,Customer andIn-transitInventoryRequirements(Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3 PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$1.00 0 $3.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000NA9,57447North America450,000North AmericaNo Impact to Packaging"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts are31Treat as Set, 5 Upper, 5 Lower, 2 ThrustShimsFile:Cylinder Block 05, 032509.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-05, 7 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly-05--Manufacturing Assumption and Quote SummaryAPPENDIX G.1-05, (5of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:OEM Assembly of Cylinder Block Components to EnginePart Number:Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 = Material + Labor

+ BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Squirter - Oil, Piston Cooler - Assembly0504-N0101-014Engine Assembly OEM Not Applicable General Assembly-OEM Mech. Assembly, HC800 10.000$0.00 $83.31 $150.19$0.00$0.10 $0.19 $0.290.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.29 $1.17Squirter - Oil, Piston Cooler - Assembly0504-N0101-014Engine Assembly OEM Not Applicable General Assembly-OEM Mech. Assembly, HC1440 10.000$0.00 $83.31 $150.19$0.00$0.06 $0.10 $0.160.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.16 $0.65Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net, PIAPurchasePrice Net,End ItemSquirter - Oil, Piston Cooler & Bolt -Piston Cooler Valve/Retainer0504-N0101-01/024SAC$8.38$2.10$0.00 $8.38Bearing Set (Upper/Lower/Thrust Shim)0590-N0101-01/02/031(UPGRADE SET) SAC$2.13$2.13$0.00 $2.13Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$12.33T1 or OEM Total Manufacturing Cost:$10.51 $0.65 $1.17 $12.33 $0.00 $0.00 $0.00 $0.00 $0.00 $12.33T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.70% 7.00% 8.00% 0.00% 15.70%(SAC)&T1 or OEM Mark-Up Values:(10.51)----- ----- -----$0.09 $0.86 $0.99 $0.00 $1.94Base Cost Impact to Vehicle:$0.00 $0.65 $1.17 $1.82 $0.09 $0.86 $0.99 $0.00 $1.94 $3.75 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$3.75Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customer andIn-transitInventoryRequirements(Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000NA9,57447North America450,000North AmericaNo Additional Packaging Affects"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts are broughtin by T2/T3 Supplier for Subassembly.31Pallet 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 Palletsize 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 WA1-3Appendix G.1-05, 8of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 06Cylinder Head SubsystemCase Study #0101MAQS WorksheetsFile:Cylinder Head 06, 032009-2.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-06, 1 of 8Cylinder Head 0601Manufacturing Assumption and Quote SummaryAPPENDIX G.1-06, (1of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Cylinder Head Assembly - Machined w. Studs, Plugs, etc.Part Number:0601-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1ACylinder Head - Machined w/o. Studs,Valves, etc.0601-N0101-011Cylinder head machining, plugassembly & testOEMNot ApplicableCNC Operator-OEM CNC Milling, LS, HC83 0.250.000$0.00 $68.07 $250.00$0.00$0.21 $3.03 $3.240.00% 0.00% 0.00% 0.00%0.00% $0.00 $3.24 $3.24Requiretooling formachining &cap assemblyRequireinvestment forcap assembly1B Cylinder Head - Heat Treat0601-N0101-021T6 Heat Treat, only considersolution step (quench andartificial age for T6 and T5approx. estimated to havesame cost impact)OEMNot ApplicableHeat Treat Operator-OEM Heat Treat, MLS, MHC81 0.250.000$0.00 $137.35 $250.00$0.00$0.42 $3.08 $3.500.00% 0.00% 0.00% 0.00%0.00% $0.00 $3.50 $3.501CCylinder Head Subassembly - CastMini Cooper0601-N0101-02-011Cylinder head casting & roughmachiningOEM Aluminum-356-T6, CastNot Applicable Not Applicable89 029.01$1.20 $0.00 $0.00 $34.81$0.00 $0.00$34.815.00% 0.00% 0.00% 0.00%5.00% $1.74 $36.55 $36.551DCylinder Head Subassembly - CastChrysler0601-N0101-02-011Cylinder head casting & roughmachiningOEMAluminum-A319-T5,CastNot Applicable Not Applicable89 0-30.99$1.15 $0.00 $0.00 -$35.64$0.00 $0.00-$35.640.00% 0.00% 0.00% 0.00%0.00% $0.00 -$35.64 -$35.640##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net, PIAPurchasePrice Net,End Item0$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 $0.000$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 $0.00TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000Returnable w.Expendable Separators9,57447North America450,000North America"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought 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 GuidesIntake and Exhaust) 0.53 - (2 M8 Studsx80) 0.12and (2 M10 Studs x60) 0.15 + (Timing ChainCover Contribution) 1.15 = 29.84Assume casting speed forChrysler and Mini Cooper Headswill be approximately the same.Thus no additional Labor orBurden costs were accounted for.5% Added Scrap Cost For A356File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-06, 2 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Cylinder Head 0601Manufacturing Assumption and Quote SummaryAPPENDIX G.1-06, (1of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Cylinder Head Assembly - Machined w. Studs, Plugs, etc.Part Number:0601-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000Returnable w.Expendable Separators9,57447North America450,000North AmericaMaterial Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$7.65T1 or OEM Total Manufacturing Cost:-$0.83 $0.63 $6.11 $5.91 $1.74 $0.00 $0.00 $0.00 $1.74 $7.65T1 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 $0.54 $0.61 $0.00 $1.20Base Cost Impact to Vehicle:-$0.83 $0.63 $6.11 $5.91 $1.79 $0.54 $0.61 $0.00 $2.94 $8.85$0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$8.85Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 600.00%$00100Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.00031PACKAGING CALCULATIONS:Negligible Affect to PackagingFile:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-06, 3 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Valve Seat 0602Manufacturing Assumption and Quote SummaryAPPENDIX G.1-06, (20f5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Seat - Intake Valve, Seat - Exhaust Valve,Part Number:0602-N0101-03/04Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net, PIAPurchasePrice Net,End Item1ASeat - Intake Valve0602-N0101-038Material difference S$0.00$0.02$0.00 $0.142ASeat - Exhaust Valve0602-N0101-048Material difference S$0.00$0.03$0.00 $0.20$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$0.34T1 or OEM Total Manufacturing Cost:$0.34 $0.00 $0.00 $0.34 $0.00 $0.00 $0.00 $0.00 $0.00 $0.34T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$0.34 $0.00 $0.00 $0.34 $0.00 $0.00 $0.00 $0.00 $0.00 $0.34 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$0.34Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%36,000,000 600.00%$00100Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS8F.O.B3,600,000NA76,59647North America450,000North America"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts are broughtin by T2/T3 Supplier for Subassembly.31Absolute Cost for Premium Valve SeatsIntake Valve, COMO 1207 => $0.18/ValveExhaust Valve, AR20 => $0.25/ValveBenchmark data from Munro on Baseline Intakeand Exhaust Valve Seat $0.16 and $0.22SETSPACKAGING CALCULATIONS:No Affect to PackagingFile:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-06, 4 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Bearing Caps 0606Manufacturing Assumption and Quote SummaryAPPENDIX G.1-06, (3of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Cap, Head (Fuel Pump & Vacuum Mount)Part Number:0606-N0101-03Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1ACap, Head (Fuel Pump & VacuumMount)0606-N0101-03-011CNC Machining S Not Applicable Mold/Cast/Sinter Operator Diecast, LMC240 0.50.000$0.00 $43.52 $100.05$0.00$0.09 $0.42 $0.510.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.51 $0.511BCap, Head (Fuel Pump & VacuumMount)0606-N0101-03-021Die casting S Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC240 0.50.610$1.10 $43.52 $100.05 $0.67 $0.09 $0.42 $1.180.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.18 $1.18Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$1.69T1 or OEM Total Manufacturing Cost:$0.67 $0.18 $0.83 $1.69 $0.00 $0.00 $0.00 $0.00 $0.00 $1.69T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.01 $0.11 $0.10 $0.04 $0.26Base Cost Impact to Vehicle:$0.67 $0.18 $0.83 $1.69 $0.01 $0.11 $0.10 $0.04 $0.26 $1.95 $0 $0Packaging Cost:$0.03Net Cost Impact to Vehicle:$1.98Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.032 $64,0790.00%2,250,000 605.00%$5,140124608657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.032TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000Returnable w. ExpendableSeparators9,57447North America450,000North AmericaPACKAGING CALCULATIONS:Option #3 Packaging with returnabledividers.Part Size: 250x 30x45Parts per layer: 1 rows of 16Number of layers: 6Number of parts/Tote = 9631File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3Appnedix G.1-06, 5 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Sealing Elements 0685Manufacturing Assumption and Quote SummaryAPPENDIX G.1-06, (4of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Gasket - Cylinder Head to BlockPart Number:0685-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net, PIAPurchasePrice Net,End ItemGasket - Cylinder Head to Block0685-N0101-011Change from 2 to 3 layergasketS$0.00$1.46$0.00 $1.460$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$1.46T1 or OEM Total Manufacturing Cost:$1.46 $0.00 $0.00 $1.46 $0.00 $0.00 $0.00 $0.00 $0.00 $1.46T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$1.46 $0.00 $0.00 $1.46 $0.00 $0.00 $0.00 $0.00 $0.00 $1.46 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$1.46Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000Returnable w.Expendable Separators9,57447North America450,000North America"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31PACKAGING CALCULATIONS:Negligible Affect to PackagingFile:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-06, 6 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly -06--Manufacturing Assumption and Quote SummaryAPPENDIX G.1-06, (5of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:OEM Assembly of Cylinder Head Components to EnginePart Number:NAWeekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1ACap, Head (Fuel Pump & Vacuum Mount)0606-N0101-03-011Head and cam assembly OEM Not ApplicableNot Applicable Not Applicable150 00.000$0.00 $0.00 $0.00$0.00 $0.00 $0.00$0.000.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.00 $0.00Requiretooling for capassemblyRequireinvestment forcap assembly1B Cap, Head (Fuel Pump & Vacuum Mount)0606-N0101-03-011Head & Cap Machining OEM Not Applicable Not ApplicableNot Applicable217 0.250.000$0.00 $0.00 $0.00$0.00 $0.00 $0.00$0.000.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.00 $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.000##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net, PIAPurchasePrice Net,End Item1ASeat - Intake/Exhaust Valves0602-N0101-038Material difference SAC$2.75$0.34$0.00 $2.752ACap, Head (Fuel Pump & VacuumMount)0606-N0101-03-011Added Part SAC$1.98$1.98$0.00 $1.983A Bolt - Cap Bearing, Camshaft 0680-N0101-014Added Part S$0.00$0.08$0.00 $0.324A Gasket - Cylinder Head to Block 0685-N0101-011Modified Part SAC$1.46$1.46$0.00 $1.465A Bolt - Manifold, Exhaust 0680-N0101-1010510 Stainless or A286 Inconel S$0.00$0.36$0.00 $3.600$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$10.11T1 or OEM Total Manufacturing Cost:$10.11 $0.00 $0.00 $10.11 $0.00 $0.00 $0.00 $0.00 $0.00 $10.11T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:(6.19)----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$3.92 $0.00 $0.00 $3.92 $0.00 $0.00 $0.00 $0.00 $0.00 $3.92 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$3.92TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000NA9,57447North America450,000North America"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31NOTES:Did not add any additional costs to add Cap, Head (Fuel Pump & VacuumMount). Assumption is additional labor& burden would be negligible inhaving 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 applicationnot recommended for use w. Aluminum due toGalvanic Action510 Series Stainless or A286 (25.5Ni/14.75Cr)File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-06, 7 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly -06--Manufacturing Assumption and Quote SummaryAPPENDIX G.1-06, (5of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:OEM Assembly of Cylinder Head Components to EnginePart Number:NAWeekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOOLING & INVESTMENT10GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING RATESMANUFACTURING COSTSMARK-UP COSTSTOTAL COSTS1F.O.B450,000NA9,57447North America450,000North AmericaPackaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000PACKAGING CALCULATIONS:Exhaust manifold bolt packaging,no change for material upgrade.Packaging cost for Cam Capbolts are included in piece price,increase in material usage only.File:Cylinder Head 06, 032009-2.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-06, 8 of 8Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 07Valve Train SubsystemCase Study #0101MAQS WorksheetsFile:Valve Trains 07, 032609.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-07, 1 of 4Valves Int.0701 & Exh.0702Manufacturing Assumption and Quote SummaryAPPENDIX G.1-07, (1of3)Printed:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Valve - Intake & Valve - OutletPart Number:0701-N0101-01 & 0702-N0101-01Weekly Component Volume: Packaging Specification:Component Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End ItemValve - Inlet 0701-N0101-011Intake valves would need to be upgraded -typical upgrade would be from nitrided JISSUH11 (Fe-1.5Si, 8.5Cr, 0.5C) toSilichromeS$0.00$0.11$0.00 $0.11Valve - Outlet 0702-N0101-011Exhaust valves would need to be upgraded -typical upgrade would be from nitrided JISSUH 35 (Fe, 9Mn, 21Cr 4Ni, 0.5C and0.4N) to Inconel head and Silichrome stem.Exhaust valves on Mini Cooper Turbo DIare Sodium filled as well. This designapproach is not considered preferred andthus will note be included in cost analysis.S$0.00$0.97$0.00 $0.970$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$1.08T1 or OEM Total Manufacturing Cost:$1.08 $0.00 $0.00 $1.08 $0.00 $0.00 $0.00 $0.00 $0.00 $1.08T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.01 $0.08 $0.09 $0.04 $0.21Base Cost Impact to Vehicle:$1.08 $0.00 $0.00 $1.08 $0.01 $0.08 $0.09 $0.04 $0.21 $1.30 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$1.30Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%36,000,000 605.00%$025016459574Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES76,59610North AmericaNorth AmericaFOB Ship Point47450,00083,600,000PACKAGING CALCULATIONS:Packaging Type:NO IMPACT TO PACKAGINGPart Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor bothFile:Valve Trains 07, 032609.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-07, 2 of 4Form Author: G. Kolwich(248)373-6000 Ext. 2411Camshafts 0706Manufacturing Assumption and Quote SummaryAPPENDIX G.1-07, (2of3)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Camshaft - Intake Machine & Exhaust MachinedPart Number:0706-N0101-02 & 0706-N0101-11Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Mutiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Camshaft - Intake Machined (MINI) 0706-N0101-021Weight Delta between Mini and ChryslerGEMA camshafts. Estimate no cost impactrelative to fabrication or machining.T1 Assembly, Mark-up Applied@ Bottom.Nodular Iron, Cast Not Applicable Not Applicable113 1 1 13.886$0.35 $0.00 $0.00 $0.00 $1.36$0.00 $0.00$1.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.36 $1.362A Camshaft - Exhaust Machined (MINI) 0706-N0101-111Weight Delta between Mini and ChryslerGEMA camshafts. Estimate no cost impactrelative to fabrication or machining.T1 Assembly, Mark-up Applied@ Bottom.Nodular Iron, Cast Not Applicable Not Applicable113 1 1 14.256$0.35 $0.00 $0.00 $0.00 $1.49$0.00 $0.00$1.49 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.49 $1.493A Camshaft - Intake Machined (MINI) 0706-B0101-021Weight Delta between Mini and ChryslerGEMA camshafts. Estimate no cost impactrelative to fabrication or machining.T1 Assembly, Mark-up Applied@ Bottom.Nodular Iron, Cast Not Applicable Not Applicable113 1 1 1-4.260$0.35 $0.00 $0.00 $0.00 -$1.49$0.00 $0.00-$1.49 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$1.49 -$1.494A Camshaft - Exhaust Machined (MINI) 0706-B0101-111Weight Delta between Mini and ChryslerGEMA camshafts. Estimate no cost impactrelative to fabrication or machining.T1 Assembly, Mark-up Applied@ Bottom.Nodular Iron, Cast Not Applicable Not Applicable113 1 1 1-4.630$0.35 $0.00 $0.00 $0.00 -$1.62$0.00 $0.00-$1.62 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$1.62 -$1.62Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item0$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up-$0.26T1 or OEM Total Manufacturing Cost:-$0.26 $0.00 $0.00 -$0.26 $0.00 $0.00 $0.00 $0.00 $0.00 -$0.26T1 or OEM Mark-Up Rates:----- ----- ----- ----- 5.00% 6.50% 6.00% 2.50% 20.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- ------$0.01 -$0.02 -$0.02 -$0.01 -$0.05Base Cost Impact to Vehicle:-$0.26 $0.00 $0.00 -$0.26 -$0.01 -$0.02 -$0.02 -$0.01 -$0.05 -$0.31 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:-$0.31Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$02501657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:Packaging Type:NO IMPACT TO PACKAGINGPart Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)File:Valve Trains 07, 032609.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-07, 3 of 4Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 0700Manufacturing Assumption and Quote SummaryAPPENDIX G.1-07, (3of3)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:OEM Engine AssemblySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Engine Assembly Impact from upgraded Valve Train componentsPart Number:0700Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)0##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Valves Intake and Exhaust Delta (Mini$-Chrysler$)8SAC$10.37$1.30$0.00 $10.372A Camshafts Exhaust & Intake Delta (Mini$-Chrysler$)1SAC($0.31)($0.31)$0.00 -$0.310$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$10.06T1 or OEM Total Manufacturing Cost:$10.06 $0.00 $0.00 $10.06 $0.00 $0.00 $0.00 $0.00 $0.00 $10.06T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:(10.06)----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$0.00Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$02501657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:Packaging Type:Part Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)No engine assembly cost impact as a result ofvalve train upgrades.File:Valve Trains 07, 032609.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-07, 4 of 4Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 08Timing Drive SubsystemCase Study #0101MAQS WorksheetsFile:Timing Drives 08 032608.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-08, 1 of 2Timing Wheels 0801Manufacturing Assumption and Quote SummaryAPPENDIX G.1-08, (1of1)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Low Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Sprocket - Crankshaft, Timing DrivePart Number:0801-N0101-01Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Mutiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End ItemSprocket - Crankshaft, Timing Drive 0801-N0101-011(Smart Sprocket royalty, mark-ups included)S$0.00$1.60$0.00 $1.600$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$1.60T1 or OEM Total Manufacturing Cost:$1.60 $0.00 $0.00 $1.60 $0.00 $0.00 $0.00 $0.00 $0.00 $1.60T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$1.60 $0.00 $0.00 $1.60 $0.00 $0.00 $0.00 $0.00 $0.00 $1.60 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$1.60Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$02501657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.0009,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTPACKAGING CALCULATIONS:Packaging Type:No Change to PackagingPart Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)File:Timing Drives 08 032608.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-08, 2 of 2Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 10Intake SubsystemCase Study #0101MAQS WorksheetsFile:Intake Systems 10 032609.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-10, 1 of 2Intake Manifold 1001Manufacturing Assumption and Quote SummaryAPPENDIX G.1-10 (1of1)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Manifold Assembly - IntakePart Number:1001-N0101-01Weekly Component Volume: Packaging Specification:Vacuum Form ReturnablesComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Manifold - Intake, Bottom Half (Mini) 1001-N0101-01-071Injection MoldingT1 Assembly, Mark-up Applied@ Bottom.Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS254 0.5 1 11.408$1.76 $43.52 $150.01 $150.01 $2.48 $0.09 $0.59 $3.15 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $3.15 $3.151B Manifold - Intake, Top Half (Mini) 1001-N0101-01-061Injection MoldingT1 Assembly, Mark-up Applied@ Bottom.Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS267 0.5 1 10.949$1.76 $43.52 $150.01 $150.01 $1.67 $0.08 $0.56 $2.31 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.31 $2.310##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.001A Manifold - Intake, Bottom Half (Chrysler) 1001-B0101-01-071Injection MoldingT1 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% 0.00% 0.00% 0.00% 0.00% $0.00 -$9.62 -$9.621B Manifold - Intake, Top Half (Chrysler) 1001-B0101-01-061Injection MoldingT1 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% 0.00% 0.00% 0.00% 0.00% $0.00 -$6.62 -$6.620##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up-$10.78T1 or OEM Total Manufacturing Cost:-$10.66 -$0.01 -$0.10 -$10.78 $0.00 $0.00 $0.00 $0.00 $0.00-$10.78T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- ------$0.05 -$0.70 -$0.65 -$0.27 -$1.67Base Cost Impact to Vehicle:-$10.66 -$0.01 -$0.10 -$10.78 -$0.05 -$0.70 -$0.65 -$0.27 -$1.67 -$12.45 $0 $0Packaging Cost:-$0.28Net Cost Impact to Vehicle:-$12.73Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.362 $723,4040.00%2,250,000 605.00%$340212827657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.362MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:MINI COOPER INTAKE MANIFOLD = $0.08Packaging Type: Option #2Part Size: 370x280x170Parts/Layer: 4 x 3 =12Number of Layers: 531Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingfor both Technology Packages)Equipment, Tooling and Fixturing for friction welding top andbottom sections of intake manifold together wouldbe lessexpensive for Mini versus GEMA. However since timeandburden rate differences would be minor, we have notincluded thedifference 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:3File:Intake Systems 10 032609.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-10, 2 of 2Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 11Fuel Induction SubsystemCase Study #0101MAQS WorksheetsFile:Fuel Induction 11 032709.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-11, 1 of 12Fuel Rail-1101-R5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-11, (1of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Low Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Fuel Rail - High PressurePart Number:1101-N0101-02Weekly Component Volume: Packaging Specification:Returnable w. Expendable SeparatorsComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Fuel Rail High Pressure 1101-N0101-021Assembly, Braze & TestT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base288 3 1 100.000$0.00 $35.51 $15.00 $150.00$0.00$0.37 $0.52 $0.89 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.89 $0.89Purchase Part - High Impact Item (Full Cost Mapping)1A Tube - Injector Rail 1101-N0101-02-061Turn & cross DrillT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Tube CNC Operator CNC Turning, MC180 0.5 1 10.600$1.65 $35.70 $45.00 $45.00 $0.99 $0.10 $0.25 $1.34 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.34 $1.342A Threaded Plug Rail Inlet 1101-N0101-02-051Machine & TapT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Bar CNC Operator CNC Turning, MC138 1 1.5 10.060$1.65 $35.70 $45.00 $67.50 $0.10 $0.26 $0.49 $0.84 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.84 $0.843A Boss High Pressure Sensor 1101-N0101-02-031Machine & TapT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Bar CNC Operator CNC Turning, LMC164 0.5 1.5 10.080$1.65 $35.70 $100.00 $150.00 $0.13 $0.11 $0.92 $1.16 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.16 $1.164A Cup Injector Port 1101-N0101-02-014PlatingT1 Assembly, Mark-up Applied@ Bottom.Plating, Fuel Rail Plating/Coating Operator Plate/Finish, SMS, MHC720 1 1 10.001$20.00 $55.17 $125.17 $125.17 $0.02 $0.08 $0.17 $0.27 0.00%0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $1.084B Cup Injector Port 1101-N0101-02-01-14Machine & Cross DrillT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Bar CNC Operator CNC Turning, HC480 2 4 10.260$1.65 $35.70 $75.00 $300.00 $0.43 $0.15 $0.63 $1.20 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.20 $4.815A Bracket Rail Mounting 1101-N0101-02-022StampingT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC610 0.5 1 10.147$1.64 $42.18 $100.10 $100.10 $0.24 $0.03 $0.16 $0.44 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.44 $0.88Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Plug Rail End 1101-N0101-02-041Stainless 304 S$0.00$0.09$0.00 $0.092A High Pressure Fuel Sensor Assembly 1101-N0101-031Pressure Sensor S$0.00$7.50$0.00 $7.500$0.00$0.00$0.00 $0.000$0.00$0.00$0.00 $0.000$0.00$0.00$0.00 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$18.59T1 or OEM Total Manufacturing Cost:$11.09 $1.81 $5.70 $18.59 $0.00 $0.00 $0.00 $0.00 $0.00 $18.59T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.30% 6.00% 4.00% 1.00% 11.30%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.06 $1.12 $0.74 $0.19 $2.10Base Cost Impact to Vehicle:$11.09 $1.81 $5.70 $18.59 $0.06 $1.12 $0.74 $0.19 $2.10 $20.70 $0 $0Packaging Cost:$0.07Net Cost Impact to Vehicle:$20.76Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.068 $136,6360.00%2,250,000 605.00%$2,740501152657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.068MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:Packaging Type: Option #3, Tote w. Vacuum FormPackPart Size: 300x55x100mmParts/Layer: 8Number of Layers:3"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 2 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411Injector-1104-R5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-11, (2of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Fuel Injector Assembly - Solenoid, 7 HolePart Number:1104-N0101-01Weekly Component Volume: Packaging Specification:Returnable Container & Internal DunnageComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Fuel Injector Assembly 1104-N0101-011Final AssemblyT1 Assembly, Mark-up Applied@ Bottom.Not Applicable Electromechanical Assembly Mech Assembly, LC, Base480 2 1 60.000$0.00 $37.35 $15.00 $90.00$0.00$0.16 $0.19 $0.34 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.34 $0.342A Seal Injector Tip 1104-N0101-01-301Overmold seal @ Injector TipT1 Assembly, Mark-up Applied@ Bottom.Nylon-HT, Inject. Electromechanical Assembly Mech Assembly, MC, Base450 1 1 10.005$4.00 $37.35 $30.00 $30.00 $0.02 $0.08 $0.07 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.173A Solenoid Body preassembled 1104-N0101-01-101Insert Windings, Ring Locator and Needle Body Assembly into Body Injector and OvermoldT1 Assembly, Mark-up Applied@ Bottom.Nylon66-40FMR, Inject. Electromechanical Assembly Mech Assembly, HC, Base450 2 1 50.030$1.54 $37.35 $45.00 $225.00 $0.05 $0.17 $0.50 $0.71 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.71 $0.714A Needle Body Assembly 1104-N0101-01-501Laser weld internal valve body (Sleeve, Needle Body, Tip and Inlet Tube)T1 Assembly, Mark-up Applied@ Bottom.Not Applicable Electromechanical Assembly Mech Assembly, MC, Base450 4 1.5 80.000$0.00 $37.35 $30.00 $360.00$0.00$0.33 $0.80 $1.13 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.13 $1.135A Needle Assembly 1104-N0101-01-111Assemble & Press SleeveT1 Assembly, Mark-up Applied@ Bottom.Not Applicable Electromechanical Assembly Mech Assembly, MC, Base450 1 1 40.000$0.00 $37.35 $30.00 $120.00$0.00$0.08 $0.27 $0.35 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.35 $0.356A Needle Injector 1104-N0101-01-131Laser Weld Ball and Seat toNeedleT1 Assembly, Mark-up Applied@ Bottom.Not Applicable Electromechanical Assembly Mech Assembly, MC, Base514 1 1 30.000$0.00 $37.35 $30.00 $90.00$0.00$0.07 $0.18 $0.25 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.25 $0.257A Metering Valve assembly 1104-N0101-01-161Laser Weld Plate to ValveT1 Assembly, Mark-up Applied@ Bottom.Not Applicable Electromechanical Assembly Mech Assembly, MC, Base514 1 1 20.000$0.00 $37.35 $30.00 $60.00$0.00$0.07 $0.12 $0.19 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.19 $0.190##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - High Impact Item (Full Cost Mapping)1A Body Injector Solenoid 1104-N0101-01-201Machine Body T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC500 0.5 5 10.140$4.56 $35.70 $45.00 $225.00 $0.64 $0.04 $0.45 $1.12 0.50% 6.50% 6.00% 1.00% 14.00% $0.16 $1.28 $1.282A Sleeve winding to inlet separator 1104-N0101-01-271Machine and Roll Splines T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC491 0.5 4.5 10.074$4.56 $35.70 $45.00 $202.50 $0.34 $0.04 $0.41 $0.79 0.50% 6.50% 6.00% 1.00% 14.00% $0.11 $0.90 $0.903A Sleeve Fuel Inlet 1104-N0101-01-281Machine T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNCOperator CNC Turning, MC485 0.5 3.5 10.041$4.56 $35.70 $45.00 $157.50 $0.19 $0.04 $0.33 $0.55 0.50% 6.50% 6.00% 1.00% 14.00% $0.08 $0.63 $0.634A Body needle 1104-N0101-01-91Machine and Roll Splines T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC460 0.5 5.5 10.043$4.56 $35.70 $45.00 $247.50 $0.20 $0.04 $0.54 $0.77 0.50% 6.50% 6.00% 1.00% 14.00% $0.11 $0.88 $0.885A Inlet Tube 1104-N0101-01-211Cut and Flare T2/T3 Hydro/CNC Form, SSLC S-Steel-304,Tube Forging Operator Cold Forge, LMC360 0.5 1 10.010$1.65 $38.52 $100.09 $100.09 $0.02 $0.05 $0.28 $0.35 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.38 $0.386A Spring Seat Lower 1104-N0101-01-141Machine T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNCOperator CNC Turning, MC450 0.25 1.5 10.0002$4.56 $35.70 $45.00 $67.50 $0.00 $0.02 $0.15 $0.17 0.50% 6.50% 6.00% 1.00% 14.00% $0.02 $0.19 $0.197A Needle valve 1104-N0101-01-241Centerless Grind T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, MC540 0.25 1.5 10.000$0.00 $35.70 $45.00 $67.50$0.00$0.02 $0.13 $0.14 0.50% 6.50% 6.00% 1.00% 14.00% $0.02 $0.16$0.167B Needle valve 1104-N0101-01-24-011Machine Heat Treat T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNC Operator CNC Turning, MC540 0.25 1.5 10.002$4.56 $35.70 $45.00 $67.50 $0.01 $0.02 $0.13 $0.15 0.50% 6.50% 6.00% 1.00% 14.00% $0.02 $0.17 $0.178A Ball Needle seat 1104-N0101-01-231EDM Mounting Pocket T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, MC720 0.25 1 10.000$0.00 $35.70 $45.00 $45.00$0.00$0.01 $0.06 $0.07 0.50% 6.50% 6.00% 1.00% 14.00% $0.01 $0.09$0.098A Ball Needle seat 1104-N0101-01-231Grind/Lap/Wash T2/T3 CNC Turning, MSMC Not ApplicableCNC Operator CNC Turning, MC540 0.25 1.5 10.000$0.00 $35.70 $45.00 $67.50$0.00$0.02 $0.13 $0.14 0.50% 6.50% 6.00% 1.00% 14.00% $0.02 $0.16$0.168A Ball Needle seat 1104-N0101-01-231Cold Head/Machine/Heat Treat T2/T3 CNC Turning, MSMCS-Steel-440C, Bar CNC Operator Cold Forge, LMC720 0.25 1 10.0003$4.56 $35.70 $100.09 $100.09 $0.00 $0.01 $0.14 $0.15 0.50% 6.50% 6.00% 1.00% 14.00% $0.02 $0.17 $0.179A Metering Valve 1104-N0101-01-181Machined T2/T3 CNC Turning, MSMC S-Steel-440C, Bar CNCOperator CNC Turning, MC470 0.25 3 10.005$4.56 $35.70 $45.00 $135.00 $0.02 $0.02 $0.29 $0.33 0.50% 6.50% 6.00% 1.00% 14.00% $0.05 $0.38 $0.3810A Plate Metering Valve 1104-N0101-01-191Stamping T2/T3 Stamp/Form, MSMC S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC766 0.25 1 10.0002$1.64 $42.18 $100.10 $100.10 $0.00 $0.01 $0.13 $0.14 0.50% 6.50% 6.00% 1.00% 14.00% $0.02 $0.17 $0.1711A Tip - Injector 1104-N0101-01-081EDM Micro Popping T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Milling, MHC480 0.5 2 10.000$0.00 $35.70 $150.15 $300.30$0.00$0.04 $0.63 $0.66 0.50% 6.50% 6.00% 1.00% 14.00% $0.09 $0.76$0.7611B Tip - Injector 1104-N0101-01-08-011Metal Injection Molding T2/T3 Powder Metal, LSHC S-Steel-440-MIM Mold/Cast/Sinter Operator Powder Metal, MHC480 1 1 10.002$13.68 $43.52 $150.14 $150.14 $0.03 $0.09 $0.31 $0.43 0.70%7.00% 8.00% 2.00% 17.70% $0.08 $0.51 $0.5112A Face seal Injector to head 1104-N0101-01-4-11Powder Metal T2/T3 Powder Metal, SSLC PM-SMF-SS410 Mold/Cast/Sinter Operator Powder Metal, LMC1440 0.5 1 10.005$4.92 $43.52 $100.14 $100.14 $0.02 $0.02 $0.07 $0.11 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.12 $0.1213A Bracket Injector hold-down 1104-N0101-01-21Stamping T2/T3 Stamp/Form, MSMC HC-Steel-4130, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC600 0.5 1 10.078$0.78 $42.18 $100.10 $100.10 $0.06 $0.04 $0.17 $0.26 0.50% 6.50% 6.00% 1.00% 14.00% $0.04 $0.30 $0.300##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Solenoid Windings 1104-N0101-01-221S$0.00$0.25$0.00 $0.252A Ring winding locator 1104-N0101-01-261S$0.00$0.08$0.00 $0.083A Spring - needle to metering valve 1104-N0101-01-151S$0.00$0.01$0.00 $0.014A Spring Needle Return 1104-N0101-01-121S$0.00$0.03$0.00 $0.035A Sleeve Screen Stop 1104-N0101-01-251S$0.00$0.01$0.00 $0.016A Screen Fuel Inlet 1104-N0101-01-61S$0.00$0.05$0.00 $0.057A circlip face seal retainer 1104-N0101-01-51S$0.00$0.02$0.00 $0.028A Compression limiter - oring 1104-N0101-01-31S$0.00$0.03$0.00 $0.039A O-Ring Injector to rail seal 1104-N0101-01-11S$0.00$0.09$0.00 $0.090$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 $0.00MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES38,29810North AmericaNorth AmericaFOB Ship Point47450,00041,800,000"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.Full QuoteModification QuoteDifferential Quote (Quote Summary includesFile:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 3 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411Injector-1104-R5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-11, (2of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Fuel Injector Assembly - Solenoid, 7 HolePart Number:1104-N0101-01Weekly Component Volume: Packaging Specification:Returnable Container & Internal DunnageComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES38,29810North AmericaNorth AmericaFOB Ship Point47450,00041,800,000Full QuoteModification QuoteDifferential Quote (Quote Summary includesMaterial Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$10.95T1 or OEM Total Manufacturing Cost:$2.16 $1.47 $6.44 $10.07 $0.03 $0.41 $0.38 $0.06 $0.89 $10.95T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.08 $0.77 $0.88 $0.44 $2.16Base Cost Impact to Vehicle:$2.16 $1.47 $6.44 $10.07 $0.11 $1.18 $1.26 $0.50 $3.05 $13.11 $0 $0Packaging Cost:$0.01Net Cost Impact to Vehicle:$13.13Cost perPieceTotalAmountLump SumPayment(%)Total # ofPieces/AmortizationPeriodNumber ofService MonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.014 $108,6800.00%9,000,000 605.00%$4,1802690726229787Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.014PACKAGING CALCULATIONS:Packaging Type: Option #3 Tote, 42 Totes/PalletPart Size: 90x55x25 mmParts/Layer per tote: 3 x 8Number of Layers per tote: 931File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 4 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411HP-Fuel Pump 1107-R5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-11, (3of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Fuel Pump - High Pressure w. Vol.Control Valve (Driven-Off Intake Cam)Part Number:1107-N0101-01Weekly Component Volume: Packaging Specification:Returnable w. Expendable SeparatorsComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1AFuel Pump - High Pressure w. Vol. ControlValve1107-N0101-011Final Assembly LineT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, HC, Base360 3 1 100.250$0.00 $35.51 $45.00 $450.00$0.00$0.30 $1.25 $1.55 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.55 $1.552A Swash Plate Drive Assembly 1107-N0101-01-091Subassembly LineT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, MC, Base360 1 1 80.000$0.00 $35.51 $30.00 $240.00$0.00$0.10 $0.67 $0.77 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.77 $0.773A Bellow piston cavity 1107-N0101-01-142Weld SubassemblyT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, MC, Base300 2 1 40.000$0.00 $35.51 $30.00 $120.00$0.00$0.24 $0.40 $0.64 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.64 $1.274A Bellow Retainer 1107-N0101-01-162Press Orifice Insert ontoBellows RetainerT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, MC, Base600 1 1 10.000$0.00 $35.51 $30.00 $30.00$0.00$0.06 $0.05 $0.11 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.11 $0.225A Shaft Drive Adapter 1107-N0101-01-09-61Press Ball, Springs and InsertT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, MC, Base300 0.5 1 10.000$0.00 $35.51 $30.00 $30.00$0.00$0.06 $0.10 $0.16 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.16 $0.16Purchase Part - High Impact Item (Full Cost Mapping)1A Housing Fuel Pump 1107-N0101-01-25-11Extrude Housing T2/T3 Cold Forge, MSMC Aluminum-7075-T6, Ext. Extruding/Drawing Operator Cold Forge, MHC96 2 1 11.800$3.21 $54.35 $150.09 $150.09 $5.78 $1.13 $1.56 $8.47 0.50% 6.50% 6.00% 1.00% 14.00% $1.19 $9.66 $9.661B Housing Fuel Pump 1107-N0101-01-25-11Machine Housing T2/T3 CNC Milling, LSHC Not Applicable CNC Operator CNC Machining, LMC121 4 14 10.000$0.00 $35.70 $25.00 $350.00$0.00$1.18 $2.88 $4.06 0.70% 7.00% 8.00% 2.00% 17.70% $0.72 $4.78$4.781C Housing Fuel Pump 1107-N0101-01-251Assemble Ball Plugs T2/T3 Mech. Assembly, SSLC Purchased Parts General AssemblyMech Assembly, LC, Base240 1 1 40.110$1.00 $35.51 $15.00 $60.00 $0.11 $0.15 $0.25 $0.51 0.30% 6.00% 4.00% 0.00% 10.30% $0.05 $0.56 $0.562A Bar Stock - Check Valve Assembly 1107-N0101-01-22-11Machining T2/T3 CNC Turning, SSLC S-Steel-304, Bar Lathe/Turning Operator S-CNC Turning, HC180 0.25 2 10.040$1.65 $37.60 $85.00 $170.00 $0.07 $0.05 $0.94 $1.06 0.30% 6.00% 4.00% 0.00% 10.30% $0.11 $1.17 $1.172B Check Valve Assembly 1107-N0101-01-221Assemble components T2/T3 Mech. Assembly, SSLC Purchased Parts General Assembly Mech Assembly, MC, Base277 1 1 20.030$1.00 $35.51 $30.00 $60.00 $0.03 $0.13 $0.22 $0.37 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.41 $0.413A Retainer Check Valve Assembly 1107-N0101-01-24-11Machining T2/T3 CNC Turning, SSLC Ni-Al-Bronze-630000, Bar Lathe/Turning Operator CNC Turning, LC144 1 2 10.075$2.44 $37.60 $25.00 $50.00 $0.18 $0.26 $0.35 $0.79 0.30% 6.00% 4.00% 0.00% 10.30% $0.08 $0.87 $0.874A Plate - Check Valve 1107-N0101-01-202Machining T2/T3 CNC Turning, SSLC S-Steel-304, Bar Lathe/Turning Operator CNC Turning, LC257 0.5 2 20.000$1.65 $37.60 $25.00 $100.00 $0.00 $0.07 $0.39 $0.46 0.30% 6.00% 4.00% 0.00% 10.30% $0.05 $0.51 $1.025A Seat - Check Valve Plate 1107-N0101-01-212Machining T2/T3 CNC Turning, SSLC S-Steel-304, Bar Lathe/Turning Operator S-CNC Turning, MC250 1 2.5 10.005$1.65 $37.60 $55.00 $137.50 $0.01 $0.15 $0.55 $0.71 0.30% 6.00% 4.00% 0.00% 10.30% $0.07 $0.78 $1.566A Retainer Check Valve 1107-N0101-01-172Machining T2/T3 CNC Turning, SSLC S-Steel-316, Bar Lathe/Turning Operator S-CNC Turning, HC251 1 3 10.050$2.44 $37.60 $85.00 $255.00 $0.12 $0.15 $1.02 $1.29 0.30% 6.00% 4.00% 0.00% 10.30% $0.13 $1.42 $2.847A Bellow piston cavity 1107-N0101-01-14-12Cut and Form Tube StockT2/T3 Hydro/CNC Form,MSMCTitanium-6AL4V, Bar Cut/Punch/Forming Operator Hydro/CNC Form, MLS, MHC225 1 1 10.010$34.37 $42.18 $150.12 $150.12 $0.34 $0.19 $0.67 $1.20 5.00%6.50% 6.00% 1.00% 18.50% $0.22 $1.42 $2.848A Spring Seat 1107-N0101-01-14-22Machining T2/T3 CNC Turning, SSLC S-Steel-316, Bar Lathe/Turning Operator S-CNC Turning, MC235 1 3 10.050$2.44 $37.60 $55.00 $165.00 $0.12 $0.16 $0.70 $0.98 0.30% 6.00% 4.00% 0.00% 10.30% $0.10 $1.09 $2.179A Top Seat and Sealing Flange 1107-N0101-01-14-32Machining T2/T3 CNC Turning, SSLC S-Steel-316, Bar Lathe/Turning Operator S-CNC Turning, MC230 1 3 10.110$2.44 $37.60 $55.00 $165.00 $0.27 $0.16 $0.72 $1.15 0.30% 6.00% 4.00% 0.00% 10.30% $0.12 $1.27 $2.5410A Bellow Retainer 1107-N0101-01-16-12Machining T2/T3 CNC Turning, SSLC A-Steel-41XXS, Bar Lathe/Turning Operator S-CNC Turning, MC231 2 5 10.500$0.78 $37.60 $55.00 $275.00 $0.39 $0.33 $1.19 $1.91 0.30% 6.00% 4.00% 0.00% 10.30% $0.20 $2.10 $4.2111A Piston High pressure pump 1107-N0101-01-112Machining T2/T3 CNC Turning, SSLC A-Steel-4140, Bar Lathe/Turning Operator S-CNC Turning, MC225 2 4 1.50.030$0.78 $37.60 $55.00 $330.00 $0.02 $0.33 $1.47 $1.82 0.30% 6.00% 4.00% 0.00% 10.30% $0.19 $2.01 $4.0212A Cap Piston contact to swash plate 1107-N0101-01-102PlatingT2/T3 Plate/Finish Mech.,SSLCNot Applicable Plating/Coating Operator Plate/Finish,SMS, LMC360 0.5 1 10.000$0.00 $55.17 $100.17 $100.17$0.00$0.08 $0.28 $0.35 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.39$0.7812B Cap Piston contact to swash plate 1107-N0101-01-102Machining T2/T3 CNC Turning, SSLC A-Steel-4140, Bar Lathe/Turning Operator S-CNC Turning, MC225 1 2 1.50.000$0.78 $37.60 $55.00 $165.00$0.00$0.17 $0.73 $0.90 0.30% 6.00% 4.00% 0.00% 10.30% $0.09 $0.99$1.9913A Casting: Swash Plate Drive Housing 1107-N0101-01-09-21Aluminum Diecast T2/T3 Diecast, SSLC Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC286 0.5 1 10.209$1.10 $43.52 $100.05 $100.05 $0.23 $0.08 $0.35 $0.66 5.00% 6.00% 4.00% 0.00% 15.00% $0.10 $0.75 $0.7513A Swash Plate Drive Housing Machined 1107-N0101-01-09-11Machine Casting T2/T3 CNC Turning, MSMC Not Applicable Mold/Cast/Sinter Operator RTM Turning, HC, PP, Base300 0.5 1 10.000$0.00 $43.52 $200.00 $200.00$0.00$0.07 $0.67 $0.74 0.50% 6.50% 6.00% 1.00% 14.00% $0.10 $0.84$0.8414A Swash Plate Assy - Cast 1107-N0101-01-09-5-31Iron Casting T2/T3 Perm. Cast, MSMC Nodular Iron, Cast Mold/Cast/Sinter Operator Perm. Cast, MHC286 3 1 10.219$0.35 $43.52 $150.06 $150.06 $0.08 $0.46 $0.53 $1.06 5.00% 6.50% 6.00% 1.00% 18.50% $0.20 $1.25 $1.2514B Swash Plate Assy 1107-N0101-01-09-5-21Machine Casting T2/T3 CNC Turning, MSMC Not Applicable CNC Operator RTM Turning, HC, PP, Base360 0.5 1 1.20.000$0.00 $35.70 $200.00 $240.00$0.00$0.05 $0.67 $0.72 0.50% 6.50% 6.00% 1.00% 14.00% $0.10 $0.82$0.8214C Swash Plate Assy 1107-N0101-01-09-5-11Heat TreatT2/T3 Plate/Finish Mech.,SSLCNot Applicable Heat Treat Operator Heat Treat, SMS, MHC250 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.19 $0.40 $0.59 0.30% 6.00% 4.00% 0.00% 10.30% $0.06 $0.65$0.6514D Swash Plate Assy 1107-N0101-01-09-51Grind T2/T3 CNC Turning, MSMC Not Applicable CNC OperatorCNC Turning, MC124 1 1 10.000$0.00 $35.70 $45.00 $45.00$0.00$0.29 $0.36 $0.65 0.50% 6.50% 6.00% 1.00% 14.00% $0.09 $0.74$0.7415A Shaft Drive Adapter PM 1107-N0101-01-09-6-51Press and Sinter T2/T3 Powder Metal, SSLC PM-SMF-IronBase Mold/Cast/Sinter Operator Powder Metal, LMC632 1 1 10.037$1.00 $43.52 $100.14 $100.14 $0.04 $0.07 $0.16 $0.26 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.29 $0.2915B Shaft Drive Adapter w/out backlash adjuster 1107-N0101-01-09-6-11Machining T2/T3 CNC Milling, SSLC Not Applicable Mold/Cast/Sinter Operator CNC Machining, LMC200 0.25 1 20.000$0.00 $43.52 $25.00 $50.00$0.00$0.05 $0.25 $0.30 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.34$0.3417A Mount Bracket HP fuel Pump 1107-N0101-01-031Ground Flat T2/T3 CNC Milling, SSLC Not Applicable Cut/Punch/Forming Operator Fine blank, LMC600 1 1 10.000$0.00 $42.18 $100.13 $100.13$0.00$0.07 $0.17 $0.24 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.26$0.2617B Mount Bracket HP fuel Pump 1107-N0101-01-03-11Fineblanked T2/T3 Fine Blank, SSLC MC-Steel-1000S, Coil Cut/Punch/Forming Operator Fine blank, LMC391 0.5 1 11.080$0.55 $42.18 $100.13 $100.13 $0.59 $0.05 $0.26 $0.90 0.30% 6.00% 4.00% 0.00% 10.30% $0.09 $1.00 $1.0018A Spacer - Mount Bracket - swash plate retainer 1107-N0101-01-021Fineblanked T2/T3 Fine Blank, SSLC Not Applicable Cut/Punch/Forming Operator Fine blank, LMC600 1 1 10.000$0.00 $42.18 $100.13 $100.13$0.00$0.07 $0.17 $0.24 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.26$0.2618B Spacer - Mount Bracket 1107-N0101-01-02-11Fineblanked T2/T3 Fine Blank, SSLC MC-Steel-1000S, Coil Cut/Punch/Forming Operator Fine blank, LMC439 0.5 1 10.557$0.55 $42.18 $100.13 $100.13 $0.31 $0.05 $0.23 $0.58 0.30% 6.00% 4.00% 0.00% 10.30% $0.06 $0.64 $0.6419A Diaphragm Temperature Compensating 1107-N0101-01-081Assemble & Test T2/T3 Mech. Assembly, SSLC PurchasedParts Cut/Punch/Forming Operator Mech Assembly, LC, Base300 1 1 30.120$1.00 $42.18 $15.00 $45.00 $0.12 $0.14 $0.15 $0.41 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.45 $0.4519BTop Stamping Diaphragm TemperatureCompensating1107-N0101-01-08-11Form & Stamp T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC621 0.5 1 10.042$0.45 $42.18 $100.10 $100.10 $0.02 $0.03 $0.16 $0.21 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.24 $0.2419CBottom Stamping Diaphragm TemperatureCompensating1107-N0101-01-08-21Form & Stamp T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC643 0.5 1 10.018$0.45 $42.18 $100.10 $100.10 $0.01 $0.03 $0.16 $0.20 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.22 $0.2220A Fitting Fuel Inlet 1107-N0101-01-061Machine T2/T3 CNC Turning, SSLC S-Steel-304, Bar Lathe/Turning Operator S-CNC Turning, MC123 0.5 1.5 10.120$1.65 $37.60 $55.00 $82.50 $0.20 $0.15 $0.67 $1.02 0.30% 6.00% 4.00% 0.00% 10.30% $0.11 $1.13 $1.13MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000Full QuoteModificationDifferential Quote (Quote Summary includesFile:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 5 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411HP-Fuel Pump 1107-R5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-11, (3of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Fuel Pump - High Pressure w. Vol.Control Valve (Driven-Off Intake Cam)Part Number:1107-N0101-01Weekly Component Volume: Packaging Specification:Returnable w. Expendable SeparatorsComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000Full QuoteModificationDifferential Quote (Quote Summary includesPurchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A 4mm Ball Plug NA7Purchase Part B1A$0.00$0.01$0.07 $0.002A Seat Fuel Outlet Fitting NA1Purchase Part B1A$0.00$0.04$0.04 $0.003A Check Ball 1107-N0101-01-22-31Purchase Part B3A$0.00$0.01$0.01 $0.004A Spring Check Ball 1107-N0101-01-22-41Purchase Part B3A$0.00$0.01$0.01 $0.005A Seat Check Ball 1107-N0101-01-22-51Purchase Part B3A$0.00$0.01$0.01 $0.006A Spring Check Valve 1107-N0101-01-231Purchase Part S$0.00$0.03$0.00 $0.037A Seat Check valve spring 1107-N0101-01-182Purchase Part S$0.00$0.06$0.00 $0.128A Spring - Check Valve 1107-N0101-01-192Purchase Part S$0.00$0.01$0.00 $0.029A Spring Bellow return 1107-N0101-01-132Purchase Part S$0.00$0.05$0.00 $0.1010A Pin Guide Pin Guide2Purchase Part S$0.00$0.02$0.00 $0.0411A O-Ring Bellow OD sealing 1107-N0101-01-152Purchase Part S$0.00$0.07$0.00 $0.1412A Tip Insert - Orifice 1107-N0101-01-16-22Purchase Part S$0.00$0.02$0.00 $0.0413A Spring HP piston 1107-N0101-01-122Purchase Part S$0.00$0.06$0.00 $0.1214A Seal Swash Plate shaft 1107-N0101-01-09-41Purchase Part S$0.00$0.19$0.00 $0.1915A Bearing Roller, Swash Plate Shaft 1107-N0101-01-09-81Purchase Part S$0.00$0.23$0.00 $0.2316A Bearing Roller Thrust, Swash Plate 1107-N0101-01-09-71Purchase Part S$0.00$0.65$0.00 $0.6517A Spring Backlash adjust 1107-N0101-01-09-6-42Purchase Part S$0.00$0.01$0.00 $0.0218A Ball Backlash Adjust 1107-N0101-01-09-6-32Purchase Part S$0.00$0.01$0.00 $0.0219A Ball Seat/Retainer 1107-N0101-01-09-6-22Purchase Part S$0.00$0.01$0.00 $0.0220A O-ring OD Seal to pump housing 1107-N0101-01-09-31Purchase Part S$0.00$0.08$0.00 $0.0821A Bolt Mount bracket 1107-N0101-01-013Purchase Part S$0.00$0.05$0.00 $0.1522A Oil Swash Plate cavity 1107-N0101-01-261Purchase Part S$0.00$0.20$0.00 $0.2023ASpring Stamping Diaphragm Temperature Compensating1107-N0101-01-08-31Purchase Part B19A$0.00$0.07$0.07 $0.0023B Diaphragm Temperature Compensating 1107-N0101-01-08-3-11Purchase Part B19A$0.00$0.05$0.05 $0.0024 Screen Fuel Inlet 1107-N0101-01-071Purchase Part S$0.00$0.08$0.00 $0.0825 Solenoid Fuel Pump Control 1107-N0101-01-051Purchase Part S$0.00$10.00$0.00 $10.0026 Bolt Control Solenoid - fuel pump 1107-N0101-01-042Purchase Part S$0.00$0.06$0.00 $0.1227Seal - High Pressure Fuel Pump to CylinderHead1185-N0101-011Purchase Part S$0.00$0.08$0.00 $0.08Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$58.06T1 or OEM Total Manufacturing Cost:$16.99 $8.24 $28.32 $53.55 $0.33 $2.30 $1.76 $0.14 $4.52 $58.06T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.41 $4.06 $4.65 $2.32 $11.44Base Cost Impact to Vehicle:$16.99 $8.24 $28.32 $53.55 $0.73 $6.36 $6.40 $2.46 $15.96 $69.50 $0 $0Packaging Cost:$0.11Net Cost Impact to Vehicle:$69.61Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.111 $221,1600.00%2,250,000 605.00%$3,880571008657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.111PACKAGING CALCULATIONS:Packaging Type: Option #3 TotesPart Size: 100x100x100Parts/Layer: 4x2Number of Layers: 3"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 6 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411Pipe Assembly 1170-R5Manufacturing Assumption and Quote SummaryAPPENDIX G1-11, (4of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Low Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Pipe Assembly - Fuel, High Pressure, Pump to RailPart Number:1170-N0101-01Weekly Component Volume: Packaging Specification:ReturnableComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Pipe - Fuel, High Pressure, Pump to Rail 1170-N0101-011Assembly Tube Nuts and Flare Tube EndsT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base225 1 1 20.000$0.00 $35.51 $15.00 $30.00$0.00$0.16 $0.13 $0.29 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.29 $0.29Purchase Part - High Impact Item (Full Cost Mapping)1A Tube Stock HP pump to rail 1170-N0101-01-011CNC Tube BendingT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Tube Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC171 0.25 1 10.060$1.65 $42.18 $100.12 $100.12 $0.10 $0.06 $0.58 $0.74 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.74 $0.742A Tube Nut HP pump to rail 1170-N0101-01-022Screw Machine Hex Bar StockT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Tube CNC Operator CNC Turning, LC288 0.5 2 10.088$1.65 $35.70 $25.00 $50.00 $0.15 $0.06 $0.17 $0.38 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.38 $0.76Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item0$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$1.80T1 or OEM Total Manufacturing Cost:$0.39 $0.34 $1.06 $1.80 $0.00 $0.00 $0.00 $0.00 $0.00 $1.80T1 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 $0.11 $0.07 $0.02 $0.20Base Cost Impact to Vehicle:$0.39 $0.34 $1.06 $1.80 $0.01 $0.11 $0.07 $0.02 $0.20 $2.00 $0 $0Packaging Cost:$0.008Net Cost Impact to Vehicle:$2.01Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.008 $16,1170.00%2,250,000 605.00%$2,02087200657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.008MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING 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 T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 7 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411Fuel Rail 1101 - GEMAManufacturing Assumption and Quote SummaryAPPENDIX G.1-11, (5of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:B0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Low Assembly ComplexitySystem Description:2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hpAnnual Component Volume: Shipping Method:Component Description:Fuel Rail AssemblyPart Number:1101-B0101-01Weekly Component Volume: Packaging Specification:Returnable w. Expendable SeparatorsComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Fuel Rail Assembly 1101-B0101-011Flow Drill Injector Cups to RailT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, HC, Base157 2 1 10.000$0.00 $35.51 $45.00 $45.00$0.00$0.45 $0.29 $0.74 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.74 $0.742A Fuel Rail Assembly 1101-B0101-011Projection Weld BracketsT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base257 1 1 10.000$0.00 $35.51 $15.00 $15.00$0.00$0.14 $0.06 $0.20 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.20 $0.203A Fuel Rail Assembly 1101-B0101-011Assembly end caps and inlettube and braze weld assembly.T1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base157 2 1 40.000$0.00 $35.51 $15.00 $60.00$0.00$0.45 $0.38 $0.84 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.84 $0.840##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - High Impact Item (Full Cost Mapping)1A Tube Injector Rail 1101-B0101-01-31Cut to length and back extrudeinletT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Tube Cut/Punch/Forming Operator Stamp/Form, SMS, LMC300 1 1 10.563$1.65 $42.18 $100.10 $100.10 $0.93 $0.14 $0.33 $1.40 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.40 $1.402A End Cap 1101-B0101-01-42StampT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC706 0.5 1 10.011$1.64 $42.18 $100.10 $100.10 $0.02 $0.03 $0.14 $0.19 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.19 $0.383A Cup Injector Port 1101-B0101-01-54StampT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC735 0.5 1 10.006$1.64 $42.18 $100.10 $100.10 $0.01 $0.03 $0.14 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.17 $0.704A Bracket Rail Mounting 1101-B0101-01-62StampT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC679 0.5 1 10.095$1.64 $42.18 $100.10 $100.10 $0.16 $0.03 $0.15 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $0.675A Inlet Tube 1101-B0101-01-71Bend & FormT1 Assembly, Mark-up Applied@ Bottom.S-Steel-304, Tube Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC600 0.5 1 10.029$1.65 $42.18 $100.12 $100.12 $0.05 $0.04 $0.17 $0.25 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.25 $0.250##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item0$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$5.18T1 or OEM Total Manufacturing Cost:$1.36 $1.46 $2.35 $5.18 $0.00 $0.00 $0.00 $0.00 $0.00 $5.18T1 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 $0.31 $0.21 $0.05 $0.58Base Cost Impact to Vehicle:$1.36 $1.46 $2.35 $5.18 $0.02 $0.31 $0.21 $0.05 $0.58 $5.76 $0 $0Packaging Cost:$0.07Net Cost Impact to Vehicle:$5.83MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 8 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411Fuel Rail 1101 - GEMAManufacturing Assumption and Quote SummaryAPPENDIX G.1-11, (5of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:B0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Low Assembly ComplexitySystem Description:2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hpAnnual Component Volume: Shipping Method:Component Description:Fuel Rail AssemblyPart Number:1101-B0101-01Weekly Component Volume: Packaging Specification:Returnable w. Expendable SeparatorsComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000Full QuoteModificationDifferential Quote (Quote Summary includesCost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.069 $138,9630.00%2,250,000 605.00%$4,180331728657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.069PACKAGING CALCULATIONS:Packaging Type: Option #3Part Size:Parts/Layer: 1X12Number of Layers 3Pallet 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, =$20.00File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 9 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411Injector-1104-GEMAManufacturing Assumption and Quote SummaryAPPENDIX G.1-11 (6of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hpAnnual Component Volume: Shipping Method:Component Description:Fuel Injector Assembly - Low Pressure, 4 HolePart Number:1104-B0101-01Weekly Component Volume: Packaging Specification:Returnable w. Expendable SeparatorsComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Injector Tip Assembly 1104-B0101-01-801Assemble Injector TipT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General AssemblyMech Assembly, MC, Base1800 0.5 1 40.000$0.00 $35.51 $30.00 $120.00$0.00$0.01 $0.07 $0.08 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.08 $0.082A Injector Needle Assembly 1104-B0101-01-701Assemble Injector NeedleT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General AssemblyMech Assembly, MC, Base480 0.5 2 30.000$0.00 $35.51 $30.00 $180.00$0.00$0.04 $0.38 $0.41 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.41 $0.413A Needle Body Assembly 1104-B0101-01-711Assemble Injector NeedleT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General AssemblyMech Assembly, MC, Base480 2 2 70.000$0.00 $35.51 $30.00 $420.00$0.00$0.15 $0.88 $1.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.02 $1.024A Solenoid Body Overmold 1104-B0101-01-721Overmold Solenoid BodyT1 Assembly, Mark-up Applied@ Bottom.Nylon66-40FMR, Inject. Electromechanical Assembly Mech Assembly, HC, Base450 2 2 10.030$1.54 $37.35 $45.00 $90.00 $0.05 $0.17 $0.20 $0.41 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.41 $0.415A Final Assembly 1104-B0101-01-731Final Assembly & TestT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, HC, Base480 2 2 60.000$0.00 $35.51 $45.00 $540.00$0.00$0.15 $1.13 $1.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.27 $1.27Purchase Part - High Impact Item (Full Cost Mapping)1A Tube Inlet 1104-B010101-01-211Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNCOperator CNC Turning, LC471 2 5.5 10.035$0.78 $35.70 $25.00 $137.50 $0.03 $0.15 $0.29 $0.47 0.50% 6.50% 6.00% 1.00% 14.00% $0.07 $0.54 $0.542A Inlet Sleeve Adaptor Stamped 1104-B0101-01-501Stamped T2/T3 Stamp/Form, SSLC A-Steel-41XXS, Bar Cut/Punch/Forming Operator Stamp/Form, SMS, MHC1200 0.5 1 10.008$0.78 $42.18 $125.10 $125.10 $0.01 $0.02 $0.10 $0.13 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.14 $0.143A Coupler Fuel Inlet 1104-B0101-01-281Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNCOperator S-CNC Turning, LC450 1 4 10.023$0.78 $35.70 $35.00 $140.00 $0.02 $0.08 $0.31 $0.41 0.50% 6.50% 6.00% 1.00% 14.00% $0.06 $0.47 $0.474A Body, Needle 1104-B0101-01-091Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNCOperator S-CNC Turning, LC465 1 4 10.049$0.78 $35.70 $35.00 $140.00 $0.04 $0.08 $0.30 $0.42 0.50% 6.50% 6.00% 1.00% 14.00% $0.06 $0.47 $0.475A Can Solenoid Housing 1104-B0101-01-511Stamped T2/T3 Stamp/Form, SSLC A-Steel-41XXS, Bar Cut/Punch/Forming Operator Stamp/Form, SMS, LMC720 0.5 1 10.043$0.78 $42.18 $100.10 $100.10 $0.03 $0.03 $0.14 $0.20 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.22 $0.226A Needle Valve 1104-B0101-01-241Stamped/Forged T2/T3 Stamp/Form, SSLC A-Steel-41XXS,Bar Cut/Punch/Forming Operator Stamp/Form, SMS, LMC600 0.5 1 10.005$0.78 $42.18 $100.10 $100.10 $0.00 $0.04 $0.17 $0.21 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.23 $0.237A Needle Valve Seat 1104-B0101-01-521Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNCOperator S-CNC Turning, LC643 0.5 2.5 10.005$0.78 $35.70 $35.00 $87.50 $0.00 $0.03 $0.14 $0.17 0.50% 6.50% 6.00% 1.00% 14.00% $0.02 $0.19 $0.198A Bracket Injector Hold down 1104-B0101-01-02-011Stamp T2/T3 Stamp/Form, SSLC SPR-Steel, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC1800 0.25 1 10.021$0.65 $42.18 $100.10 $100.10 $0.01 $0.01 $0.06 $0.07 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.08 $0.088B Bracket Injector Hold down 1104-B0101-01-021Heat Treat & Plate T2/T3 Heat Treat, SSLC General Underhood Plating Plating/Coating Operator Plate/Finish,SMS, LMC1800 0.5 1 10.001$15.00 $55.17 $100.17 $100.17 $0.02 $0.02 $0.06 $0.09 0.30%6.00% 4.00% 0.00% 10.30% $0.01 $0.09 $0.099A Injector Tip Housing 1104-N0101-01-081Machine T2/T3 CNC Turning, MSMC A-Steel-41XXS, Bar CNCOperator S-CNC Turning, MC450 1 4.5 10.003$0.78 $35.70 $55.00 $247.50 $0.00 $0.08 $0.55 $0.63 0.50% 6.50% 6.00% 1.00% 14.00% $0.09 $0.72 $0.7210A Plate - Injector Tip 1104-N0101-01-08-021Stamp T2/T3 CNC Turning, MSMC HC-Steel-4130, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC3600 0.25 1 10.000$0.78 $42.18 $100.10 $100.10 $0.00 $0.00 $0.03 $0.03 0.50% 6.50% 6.00% 1.00% 14.00% $0.00 $0.04 $0.0410B Plate - Injector Tip 1104-N0101-01-08-011Laser Injector Holes T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Milling, LMC3600 0.25 1 10.000$0.00 $35.70 $125.15 $125.15$0.00$0.00 $0.03 $0.04 0.50% 6.50% 6.00% 1.00% 14.00% $0.01 $0.04$0.0411A Tip Relief Plate 1104-B0101-01-701Stamp T2/T3 Stamp/Form, SSLC HC-Steel-4130, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC2057 0.25 1 10.000$0.78 $42.18 $100.10 $100.10 $0.00 $0.01 $0.05 $0.05 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.06 $0.06Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Sleeve Screen-Screen Stop 1104-B0101-01-251S$0.00$0.01$0.00 $0.012A Screen, Fuel Inlet 1104-B0101-01-061S$0.00$0.05$0.00 $0.053A Retainer Metering valve, Upper Spring Seat 1104-B0101-01-171S$0.00$0.02$0.00 $0.024A Ball Needle Seat 1104-B0101-01-231(Used Pricing from MiniInjector)S$0.00$0.41$0.00 $0.415A Spring - Needle Return 1104-B0101-01-121S$0.00$0.03$0.00 $0.036A Solenoid Winding Assembly 1104-N0101-01-221S$0.00$0.15$0.00 $0.157A O-Ring Injector to Rail Seal 1104-B0101-01-611S$0.00$0.09$0.00 $0.098A O-Ring Injector to Head 1104-B0101-01-621S$0.00$0.05$0.00 $0.059A Sleeve Injector Head 1104-B0101-01-631S$0.00$0.02$0.00 $0.0210A Injector Slip Washer 1104-B0101-01-641S$0.00$0.01$0.00 $0.01Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$7.31T1 or OEM Total Manufacturing Cost:$1.03 $1.04 $4.86 $6.93 $0.01 $0.19 $0.16 $0.02 $0.38 $7.31T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.05 $0.51 $0.59 $0.29 $1.44Base Cost Impact to Vehicle:$1.03 $1.04 $4.86 $6.93 $0.06 $0.70 $0.74 $0.31 $1.82 $8.76 $0 $0Packaging Cost:$0.01Net Cost Impact to Vehicle:$8.77MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES38,29810North AmericaNorth AmericaFOB Ship Point47450,00041,800,000"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 10 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411Injector-1104-GEMAManufacturing Assumption and Quote SummaryAPPENDIX G.1-11 (6of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Chrysler GEMA, 2.4L I4, 16V DOHC, NA, dVVT, 173hpAnnual Component Volume: Shipping Method:Component Description:Fuel Injector Assembly - Low Pressure, 4 HolePart Number:1104-B0101-01Weekly Component Volume: Packaging Specification:Returnable w. Expendable SeparatorsComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES38,29810North AmericaNorth AmericaFOB Ship Point47450,00041,800,000Full QuoteModificationDifferential Quote (Quote Summary includesCost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.012 $97,9610.00%9,000,000 605.00%$4,42022103686229787Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.012PACKAGING CALCULATIONS:Packaging Type: Option #3 TotePart Size: 90x55x25 mmParts/Layer: 3 x 8Number of Layers: 9File:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 11 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly-1100 R5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-11, (7of7)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:OEM Engine AssemblySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:OEM Assembly of Fuel Induction Components to EnginePart Number:1100Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Fuel Rail - High Pressure 1101-N0101-021Install Fuel Rail to CylinderHead(Two AdditionalFasteners Over Base GEMAEngine)OEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Engine Assembly,OEM257 1 1 10.000$0.00 $83.31 $150.21 $150.21$0.00$0.32 $0.58 $0.91 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.91 $0.912A Fuel Injector Assembly - Solenoid, 7 Hole 1104-N0101-014Install Fuel Injectors toCylinder Head, ConsideredWash to Base EngineOEM Assembly, Mark-upApplied @ Bottom.Not Applicable Not Applicable Not Applicable451 1 1 10.000$0.00 $0.00 $0.00 $0.00$0.00 $0.00 $0.00$0.00 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.00 $0.00Fuel Pump - High Pressure w. Vol.Control Valve(Driven-Off Intake Cam)1107-N0101-011Install Fuel Pump to CylinderHead, 3 FastenersOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Engine Assembly,OEM171 1 1 10.000$0.00 $83.31 $150.21 $150.21$0.00$0.49 $0.88 $1.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.36 $1.36Pipe Assembly - Fuel, High Pressure, Pump toRail1170-N0101-011Install High Pressure PipeBetween Fuel Rail and Pump.Run Down Two Tube NutsOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Engine Assembly,OEM257 1 1 10.000$0.00 $83.31 $150.21 $150.21$0.00$0.32 $0.58 $0.91 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.91 $0.91Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Fuel Rail - High Pressure (w. HP Sensor) 1101-N0101-021(Mini Cooper) SAC$20.76$20.76$0.00 $20.762A Fuel Injector Assembly - Solenoid, 7 Hole 1104-N0101-014(Mini Cooper) SAC$52.50$13.13$0.00 $52.503AFuel Pump - High Pressure w. Vol.Control Valve(Driven-Off Intake Cam)1107-N0101-011(Mini Cooper) SAC$69.61$69.61$0.00 $69.614APipe Assembly - Fuel, High Pressure, Pump toRail1170-N0101-011(Mini Cooper) SAC$2.01$2.01$0.00 $2.010$0.00$0.00$0.00 $0.005A Fuel Rail Assembly 1101-B0101-011Chrysler GEMA SAC($5.83)($5.83)$0.00 -$5.836A Fuel Injector Assembly - Low Pressure, 4 Hole 1104-B0101-014Chrysler GEMA SAC($35.07)($8.77)$0.00 -$35.070$0.00$0.00$0.00 $0.007A Bolt - Fuel Pump (to head) 1180-N0101-023S$0.00$0.03$0.00 $0.098A Bolt - Fuel Rail (to head) 1180-N0101-012S$0.00$0.03$0.00 $0.06Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$107.31T1 or OEM Total Manufacturing Cost:$104.14 $1.13 $2.04 $107.31 $0.00 $0.00 $0.00 $0.00 $0.00 $107.31T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:(103.99)----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$0.15 $1.13 $2.04 $3.33 $0.00 $0.00 $0.00 $0.00 $0.00 $3.33 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$3.33Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:No Packaging Considerations Required.Packaging Type:Part Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:Fuel Induction 11 032709.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-11, 12 of 12Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 12Exhaust SubsystemCase Study #0101MAQS WorksheetsFile:Exhaust Subsystem 12 033009.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-12, 1 of 6Manifold Exhaust 1201Manufacturing Assumption and Quote SummaryAPPENDIX G.1-12 (1of4)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Manifold - Exhaust, Dual WallPart Number:1201-N0101-01Weekly Component Volume: Packaging Specification:Component Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Manifold - Exhaust, Dual Wall (Mini) 1201-N0101-01-021CastT1 Assembly, Mark-up Applied@ Bottom.NiResist Iron, D5S, Cast Mold/Cast/Sinter Operator Sand Cast, HMC141 6 1.5 27.760$3.50 $43.52 $150.07 $450.21 $27.16 $1.85 $3.19 $32.20 10.00% 0.00% 0.00% 0.00% 10.00% $3.22 $35.42 $35.421B Manifold - Exhaust, Dual Wall (Mini) 1201-N0101-01-011Heat Treat, Pre MachineT1 Assembly, Mark-up Applied@ Bottom.Not Applicable Heat Treat Operator Heat Treat, MLS, MHC129 1 3 10.000$0.00 $46.52 $250.00 $750.00$0.00$0.36 $5.83 $6.20 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $6.20 $6.201C Manifold - Exhaust, Dual Wall (Mini) 1201-N0101-011MachiningT1 Assembly, Mark-up Applied@ Bottom.Not Applicable Mold/Cast/Sinter Operator CNC Machining, MHC120 3 3 1.50.000$0.00 $43.52 $45.00 $202.50$0.00$1.09 $1.69 $2.78 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.78 $2.782A Manifold - Exhaust, (Chrysler) 1201-B0101-01-021CastT1 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% 0.00% 0.00% 0.00% 5.00% -$0.39 -$8.28 -$8.282B Manifold - Exhaust, Dual Wall (Chrysler) 1201-B0101-01-011Heat Treat, Pre MachineT1 Assembly, Mark-up Applied@ Bottom.Not Applicable Heat Treat Operator Heat Treat, MLS, MHC-125 1 2.5 10.000$0.00 $46.52 $250.00 $625.00$0.00-$0.37 -$5.00 -$5.37 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$5.37 -$5.372C Manifold - Exhaust, Dual Wall (Chrysler) 1201-B0101-011MachiningT1 Assembly, Mark-up Applied@ Bottom.Not Applicable Mold/Cast/Sinter Operator CNC Machining, MHC-120 3 3 10.000$0.00 $43.52 $45.00 $135.00$0.00-$1.09 -$1.13 -$2.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 -$2.21 -$2.210##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item0$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$28.52T1 or OEM Total Manufacturing Cost:$22.64 $0.03 $3.03 $25.70 $2.83 $0.00 $0.00 $0.00 $2.83 $28.52T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.14 $1.85 $1.71 $0.71 $4.42Base Cost Impact to Vehicle:$22.64 $0.03 $3.03 $25.70 $2.97 $1.85 $1.71 $0.71 $7.25 $32.95 $0 $0Packaging Cost:-$0.12Net Cost Impact to Vehicle:$32.829,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENT"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesCasting & Machining Assumptions:Casting: Assumption processing timeincrease due to part complexity and materialgrade is offset by reduction in materialvolume.Machining: 50% premium paid onmachining NiResist material over basenodular cast iron.File:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-12, 2 of 6Form Author: G. Kolwich(248)373-6000 Ext. 2411Manifold Exhaust 1201Manufacturing Assumption and Quote SummaryAPPENDIX G.1-12 (1of4)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Manifold - Exhaust, Dual WallPart Number:1201-N0101-01Weekly Component Volume: Packaging Specification:Component Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTFull QuoteModificationDifferential Quote (Quote Summary includesCost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.152 $303,1910.00%2,250,000 605.00%$38079872657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.152PACKAGING CALCULATIONS:MINIPackaging Type: Option #2Part Size:320x120X115Parts/Layer: 3x10Number of Layers: 7Cost $0.03/PartPACKAGING CALCULATIONS:GEMAPackaging Type: Option #2Part Size: 380x280x130Parts/Layer:3x4Number of Layers: 6Cost = $0.076/PartFile:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-12, 3 of 6Form Author: G. Kolwich(248)373-6000 Ext. 2411Exh. Brkt's-Heat Shields 1275Manufacturing Assumption and Quote SummaryAPPENDIX G.1-12, (2of4)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Low Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Bracket Subassembly- Heat Shield, Top, TurboPart Number:1275-N0101-02Weekly Component Volume: Packaging Specification:(Included in piece cost)Component Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Bracket Subassembly- Heat Shield, Top, Turbo 1275-N0101-021Install Ceramic Fiber Paper(Fiberfrax 440), crimp and form.T1 Assembly, Mark-up Applied@ Bottom.Fiberfrax 440 General Assembly Mech Assembly, MC, Base450 1 1 1256$0.01 $35.51 $30.00 $30.00 $1.77 $0.08 $0.07 $1.91 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.91 $1.910##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$1.91T1 or OEM Total Manufacturing Cost:$1.77 $0.08 $0.07 $1.91 $0.00 $0.00 $0.00 $0.00 $0.00 $1.91T1 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 $0.20Base Cost Impact to Vehicle:$1.77 $0.08 $0.07 $1.91 $0.01 $0.11 $0.08 $0.00 $0.20 $2.11 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$2.11Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.0009,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTPACKAGING CALCULATIONS:Packaging Type:Part Size:Parts/Layer:Number of Layers:31Full QuoteModificationDifferential Quote (Quote Summary includesMaterial Size "In^2" and MaterialCost $/Inch^2.File:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-12, 4 of 6Form Author: G. Kolwich(248)373-6000 Ext. 2411Exhaust Sealing 1285Manufacturing Assumption and Quote SummaryAPPENDIX G.1-12, (3of4)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Low Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Bracket Subassembly - Exhaust Manifold w. Integrated GasketPart Number:1275-N0101-01Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1ABracket Subassembly - Exhaust Manifold w.Integrated Gasket1275-N0101-011Upgrade from 2 to 3 layerexhaust gasket. Onlyconsidering gasket, noconsideration required for heatshield mounting.S$0.00$0.95$0.00 $0.950$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$0.95T1 or OEM Total Manufacturing Cost:$0.95 $0.00 $0.00 $0.95 $0.00 $0.00 $0.00 $0.00 $0.00 $0.95T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$0.95 $0.00 $0.00 $0.95 $0.00 $0.00 $0.00 $0.00 $0.00 $0.95 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$0.95Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.0009,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTPACKAGING CALCULATIONS:Packaging Type:Part Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-12, 5 of 6Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 1200Manufacturing Assumption and Quote SummaryAPPENDIX G.1-12 (4 of4)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:OEM Engine AssemblySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Vehicle Operations or Engine Assembly of Exhaust ComponentsPart Number:1200Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)0##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.000##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End ItemManifold Exhaust 1201-N0101-011SAC$32.82$32.82$0.00 $32.82Exhaust Brackets/Heat Shields 1275-N0101-021SAC$2.11$2.11$0.00 $2.11Exhaust Sealing 1275(85)-N0101-011SAC$0.95$0.95$0.00 $0.95Nut- Manifold Exhaust to Cylinder Head 1280-N0101-0110S$0.00$0.18$0.00 $1.83Nut - Turbo to C.C. Catalytic Converter 1280-N0101-063S$0.00$0.02$0.00 $0.06Nut - Exhaust Manifold to Turbo 1280-N0101-074(0.193-0.05) S$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$37.77T1 or OEM Total Manufacturing Cost:$37.77 $0.00 $0.00 $37.77 $0.00 $0.00 $0.00 $0.00 $0.00 $37.77T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:(35.88)----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$1.89 $0.00 $0.00 $1.89 $0.00 $0.00 $0.00 $0.00 $0.00 $1.89 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$1.89Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.0009,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTPACKAGING CALCULATIONS:Packaging Type:No change to packagingPart Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesCover cost of Nut-Exhaust Manifold to Turbo in AirInduction Engine Assembly Cost Sheet.No differential labor/burden costs incurred to assemblyexhaust system components.File:Exhaust Subsystem 12 033009.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-12, 6 of 6Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 13Lubrication SubsystemCase Study #0101MAQS WorksheetsFile:13 Lubrication Subsystem 032309.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-13, 1 of 11Oil Pump 1302Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13 (1of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Oil Pump AssemblyPart Number:1302-N0101-01Weekly Component Volume: Packaging Specification:Component Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Oil Pump Assembly 1302-N0101-011Increase in Pump Capacity 15-20% (13%PCJ & 5% Turbo)S$0.00$3.08$0.00 $3.080$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$3.08T1 or OEM Total Manufacturing Cost:$3.08 $0.00 $0.00 $3.08 $0.00 $0.00 $0.00 $0.00 $0.00 $3.08T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.02 $0.22 $0.25 $0.12 $0.61Base Cost Impact to Vehicle:$3.08 $0.00 $0.00 $3.08 $0.02 $0.22 $0.25 $0.12 $0.61 $3.69 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$3.69Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:No Packaging Updates RequiredPackaging Type:Part Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 2 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Filter Cooler Assembly 1306Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13 (2of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Filter Cooler Assembly - Oil (Includes Seals)Part Number:1306-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Oil Cooler Adapter/Base Plate Subassembly 1306-N0101-01-02-1A1Toggle Lock Adaptor andBase Plate TogetherS Not Applicable General Assembly Mech. Assembly, MC300 10.000$0.00 $35.51 $125.19$0.00$0.12 $0.42 $0.540.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.54 $0.542A Oil Cooler 1306-N0101-01-021Fixture and Braze Weld S Not Applicable General Assembly Mech. Assembly, MC180 10.000$0.00 $35.51 $125.19$0.00$0.20 $0.70 $0.890.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.89 $0.893AFilter Cooler Assembly - Oil (Includes Seals &aux1306-N0101-011Final Assembly of filter/coolerassembly (Only ConsiderTurbo/DI Driven Costs)S Not Applicable General Assembly Mech. Assembly, MC240 50.000$0.00 $35.51 $125.19$0.00$0.74 $0.52 $1.260.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.26 $1.26Purchase Part - High Impact Item (Full Cost Mapping)1A Housing Oil Filter Preassembled 1306-N0101-01-081Casting (50% Mass Attributedto Turbo/DI oil cooler features)S Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC160 10.900$1.10 $43.52 $100.05 $0.99 $0.27 $0.63 $1.890.30% 6.00% 4.00% 0.00%10.30% $0.19 $2.08 $2.081B Housing Oil Filter Preassembled 1306-N0101-01-081Machine Casting Features(Hole Attributed to Turbo/DIOnly)S Not Applicable Mold/Cast/Sinter Operator Perm. Cast,MHC150 10.000$0.00 $43.52 $150.06$0.00$0.29 $1.00 $1.290.30% 6.00% 4.00% 0.00%10.30% $0.13 $1.42 $1.422A Oil Cooler Adapter Plate 1306-N0101-01-02-11Stamping SAluminum-3003/4047B,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, LMC480 0.50.253$2.10 $42.18 $100.10 $0.53 $0.04 $0.21 $0.780.30% 6.00% 4.00% 0.00%10.30% $0.08 $0.86 $0.863A Oil Cooler Base Plate 1306-N0101-01-02-21Stamping SAluminum-3003/4047B,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, LMC480 0.50.253$2.10 $42.18 $100.10 $0.53 $0.04 $0.21 $0.780.30% 6.00% 4.00% 0.00%10.30% $0.08 $0.86 $0.864A Oil Cooler Cooling Plate stack-Lance 1306-N0101-01-02-35Stamping SAluminum-3003/4047A,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, LMC581 10.018$1.65 $42.18 $100.10 $0.03 $0.07 $0.17 $0.270.30% 6.00% 4.00% 0.00%10.30% $0.03 $0.30 $1.525A Oil Cooler Cooling Plate stack 1306-N0101-01-02-317Stamping SAluminum-3003/4047A,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, LMC1161 0.50.018$1.65 $42.18 $100.10 $0.03 $0.02 $0.09 $0.130.30% 6.00% 4.00% 0.00%10.30% $0.01 $0.15 $1.046A Oil Cooler Top Plate 1306-N0101-01-02-41Stamping SAluminum-3003/4047A,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, LMC581 0.50.062$1.65 $42.18 $100.10 $0.10 $0.04 $0.17 $0.310.30% 6.00% 4.00% 0.00%10.30% $0.03 $0.34 $0.34Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Gasket housing to block Oil 1306-N0101-01-091S$0.00$0.07$0.00 $0.072A Gasket housing to block - coolant 1306-N0101-01-101S$0.00$0.06$0.00 $0.063A Gasket Oil Cooler Odd Shape 1306-N0101-01-071S$0.00$0.06$0.00 $0.064A Gasket Oil Cooler Square 1306-N0101-01-061S$0.00$0.06$0.00 $0.065A Gasket Oil Cooler Oval 1306-N0101-01-051S$0.00$0.06$0.00 $0.066A Gasket Oil Cooler Round 1306-N0101-01-041S$0.00$0.05$0.00 $0.057A Bolt Oil Cooler to housing 1306-N0101-01-035S$0.00$0.01$0.00 $0.068ATube Assembly- Oil, Cooler/Filter Ass'y Outletto Turbocharger1370-N0101-011SAC$4.09$4.09$0.00 $4.090$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 $0.00TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w. ExpendableSeparators109,57447450,0001450,000"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 3 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Filter Cooler Assembly 1306Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13 (2of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Filter Cooler Assembly - Oil (Includes Seals)Part Number:1306-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteModification QuoteXEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w. ExpendableSeparators109,57447450,0001450,000Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$15.33T1 or OEM Total Manufacturing Cost:$7.02 $2.23 $5.31 $14.57 $0.02 $0.44 $0.29 $0.00 $0.76 $15.33T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%(SAC)&T1 or OEM Mark-Up Values:(4.09)----- ----- -----$0.08 $1.00 $0.92 $0.38 $2.38Base Cost Impact to Vehicle:$2.93 $2.23 $5.31 $10.48 $0.10 $1.44 $1.21 $0.38 $3.13 $13.61 $0 $0Packaging Cost:$0.16Net Cost Impact to Vehicle:$13.78Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.068 $136,7780.00%2,250,000 605.00%$20068484657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.10$1.00 8 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.164Option #2 Packaging with expendabletier dividers and pads.Two parts nested together.Part Packaging Volume: 300x360x120Parts/Layer = 3x4=12Number of Layers = 731File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 4 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Ass'y Turbo to Block 1370Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13, (3of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Tube Assembly - Oil, Turbo to Engine BlockPart Number:1370Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Tube Assembly - Oil, Turbo to Engine Block 1370-N0101-021Assemble End Fittings and Orings onto Tube and Crimp inPlace. Pressure TestS Not Applicable General Assembly Mech. Assembly, LC240 20.000$0.00 $35.51 $100.19$0.00$0.30 $0.42 $0.710.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.71 $0.71Purchase Part - High Impact Item (Full Cost Mapping)1A Tube Stock - Oil, Turbo to Engine Block 1370-N0101-02-21Tube Bending S LC-Steel-1215, Tubing Cut/Punch/Forming OperatorHydro/CNC Form, SMS, LMC360 0.50.210$0.62 $42.18 $100.12 $0.13 $0.06 $0.28 $0.470.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.47 $0.471B Tube Stock - Oil, Turbo to Engine Block 1370-N0101-02-11Flare Tube Ends S Not Applicable Cut/Punch/Forming OperatorHydro/CNC Form, SMS, LMC240 10.210$0.00 $42.18 $100.12$0.00$0.18 $0.42 $0.590.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.59 $0.591C Tube Stock - Oil, Turbo to Engine Block 1370-N0101-02-31Plate SGeneral Underhood PlatingPlating/Coating OperatorPlate/Finish, SMS, MHC720 10.001$15.00 $55.17 $125.17 $0.02 $0.08 $0.17 $0.270.30% 6.00% 4.00% 0.00%10.30% $0.03 $0.29 $0.292A Fitting Tube End 1370-N0101-02-42Forge Blank S MC-Steel-1018, Bar Forging Operator ColdForge, LMC900 0.50.165$0.55 $38.52 $100.09 $0.09 $0.02 $0.11 $0.220.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.22 $0.452B Fitting Tube End 1370-N0101-02-42Machine S Not Applicable CNC Operator CNC Milling, SMS, LC360 0.50.000$0.00 $35.70 $100.15$0.00$0.05 $0.28 $0.330.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.33 $0.662C Fitting Tube End 1370-N0101-02-42Plate SGeneral Underhood PlatingPlating/Coating OperatorPlate/Finish, SMS, MHC1800 10.001$15.00 $55.17 $125.17 $0.02 $0.03 $0.07 $0.120.30% 6.00% 4.00% 0.00%10.30% $0.01 $0.13 $0.25Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A O-ring - Tube Fitting 1370-N0101-02-31S$0.00$0.06$0.00 $0.060$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$3.48T1 or OEM Total Manufacturing Cost:$0.42 $0.81 $2.20 $3.43 $0.00 $0.03 $0.02 $0.00 $0.05 $3.48T1 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 $0.21 $0.14 $0.00 $0.36Base Cost Impact to Vehicle:$0.42 $0.81 $2.20 $3.43 $0.01 $0.24 $0.16 $0.00 $0.41 $3.84 $0 $0Packaging Cost:$0.06Net Cost Impact to Vehicle:$3.90TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 5 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Ass'y Turbo to Block 1370Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13, (3of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Tube Assembly - Oil, Turbo to Engine BlockPart Number:1370Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.055 $110,2060.00%2,250,000 605.00%$4,420252304657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.055Option #3: Returnable Totes andDividersPart Nest Size: 300x30x90Parts per layer 16Number of Layers = 3= 48 Parts per ToteFile:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 6 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Ass'y Oil Cool-Turbo1370Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13, (4of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to TurbochargerPart Number:1370-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Fitting Hose Oil Cooler to Turbo 1306-N0101-01-11-21Braze weld Tube Fitting toBracket MountS Not Applicable General Assembly Mech. Assembly, LC257 10.000$0.00 $35.51 $100.19$0.00$0.14 $0.39 $0.530.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.53 $0.531BTube Assembly- Oil, Cooler/Filter Ass'y Outletto Turbocharger1306-N0101-01-11(1370-N0101-01)1Crimp End Fitting to Hose andAdd Protective Heat Shield,Oring and ClampS Not Applicable General Assembly Mech. Assembly, LC240 30.000$0.00 $35.51 $100.19$0.00$0.44 $0.42 $0.860.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.86 $0.86Purchase Part - High Impact Item (Full Cost Mapping)1A Hose Oil Cooler to Turbo 1306-N0101-01-11-11Extrude & Shape Hose SSBR-Fiber Rein.W. Outer Wrap,ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC545 1.50.007$2.05 $54.35 $100.04 $0.01 $0.15 $0.18 $0.350.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.35 $0.352A Tube Fitting end 1306-N0101-01-11-2-11Machining S LC-Steel-1215, Tubing CNC Operator CNC Turning, LMC200 0.250.150$0.62 $35.70 $100.00 $0.09 $0.04 $0.50 $0.640.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.64 $0.643A Bracket Tube Fitting end attach 1306-N0101-01-11-2-1-11Fine blank, LMC S LC-Steel-1000S, Coil Cut/Punch/Forming Operator Fine blank, LMC1000 0.50.207$0.45 $42.18 $100.13 $0.09 $0.02 $0.10 $0.210.30% 6.00% 4.00% 0.00%10.30% $0.02 $0.24 $0.24Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net, PIAPurchase PriceNet, End Item1A Collar Tube fitting attachment 1306-N0101-01-11-2-1-21S$0.00$0.05$0.00 $0.052A Heat Shield, Hose 1306-N0101-01-11-21S$0.00$0.75$0.00 $0.753A Hose Clamp 1306-N0101-01-11-31S$0.00$0.22$0.00 $0.224A O-ring 1306-N0101-01-11-41S$0.00$0.06$0.00 $0.060$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotal Mark-up$3.68T1 or OEM Total Manufacturing Cost:$1.27 $0.80 $1.59 $3.66 $0.00 $0.01 $0.01 $0.00 $0.02 $3.68T1 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 $0.22 $0.15 $0.00 $0.38Base Cost Impact to Vehicle:$1.27 $0.80 $1.59 $3.66 $0.01 $0.23 $0.16 $0.00 $0.40 $4.06 $0 $0Packaging Cost:$0.03Net Cost Impact to Vehicle:$4.09TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 7 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Ass'y Oil Cool-Turbo1370Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13, (4of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Tube Assembly- Oil, Cooler/Filter Ass'y Outlet to TurbochargerPart Number:1370-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customer andIn-transitInventoryRequirements(Weeks)Supplier,Customer and Intransit InventoryRequirements(Parts)Rack/Pallet Investment Amortization:$0.026 $51,9500.00%2,250,000 605.00%$5,86096480657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3 PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.026Packaging Option #3: Returnable Totes &DividersPart Nesting Size: 220x30x30Parts per Layer: 15Layers per Tote: 9File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 8 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Oil - Synthetic 1399Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13, (5of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Oil - SyntheticPart Number:1399-N0101-08Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A OIL - ENGINE 0W-40 ILSAC GF3 MS-10725 NA1S$0.00$4.00$0.00 $4.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$4.00T1 or OEM Total Manufacturing Cost:$4.00 $0.00 $0.00 $4.00 $0.00 $0.00 $0.00 $0.00 $0.00 $4.00T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$4.00 $0.00 $0.00 $4.00 $0.00 $0.00 $0.00 $0.00 $0.00 $4.00 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$4.00Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000Standard Pallet L4'xW4'xD3'Area = 122cm x 114 cm = 1440 sq. cmDepth = 86 cmPart Size:Parts Per Layer:Parts Per Pallet:"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 9 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 1300Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13, (6of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:OEM Assembly of Additional or Revised Lubrication Components to EnginePart Number:1300-N0101-00Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotal Mark-up Cost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Tube Assembly - Oil, Turbo to Engine Block 1370-N0101-021Install Tube Assembly toEngineOEM Not Applicable General Assembly-OEM Engine Assembly, OEM129 10.000$0.00 $83.31 $150.21$0.00$0.65 $1.17 $1.820.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.82 $1.822ATube Assembly- Oil, Cooler/Filter Ass'y Outletto Turbocharger1306-N0101-01-11(1370-N0101-01)1Install Hose to TurboAssembly, Run Down BoltOEM Not Applicable General Assembly-OEM Engine Assembly, OEM240 10.000$0.00 $83.31 $150.21$0.00$0.35 $0.63 $0.970.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.97 $0.973A Filter Cooler Assembly - Oil (Includes Seals) 1306-N0101-011Install Filter Cooler Assemblyand Run Down 4 BoltsOEM Not Applicable General Assembly-OEM Engine Assembly, OEM180 10.000$0.00 $83.31 $150.21$0.00$0.46 $0.83 $1.300.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.30 $1.30Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccount CostPurchasePrice/ UnitPurchasePrice Net, PIAPurchase PriceNet, End Item1ABolt - Tube Assembly , Oil, Turbo Outlet & BlockI1380-N0101-062Banjo Bolts S$0.00$0.24$0.00 $0.482AWasher - Bolt - Tube Assembly , Oil, TurboOutlet1380-N0101-094Banjo Washers S$0.00$0.03$0.00 $0.123A Tube Assembly - Oil, Turbo to Engine Block 1370-N0101-021SAC$3.84$3.84$0.00 $3.844A Bolt hose oil cooler to turbo 1306-N0101-01-121S$0.00$0.05$0.00 $0.055A Bolt - Filter Cooler Assembly 1380-N0101-084S$0.00$0.07$0.00 $0.286A Filter Cooler Assembly - Oil (Includes Seals) 1306-N0101-011SAC$13.78$13.78$0.00 $13.787ATube Assembly- Oil, Cooler/Filter Ass'y Outletto Turbocharger1370-N0101-011SAC$4.09$4.09$0.00 $4.09Material Labor Burden TMC Scrap SG&A Profit ED&TTotal Mark-up$26.72T1 or OEM Total Manufacturing Cost:$22.64 $1.46 $2.63 $26.72 $0.00 $0.00 $0.00 $0.00 $0.00 $26.72T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 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 $0.00Base Cost Impact to Vehicle:$0.93 $1.46 $2.63 $5.02 $0.00 $0.00 $0.00 $0.00 $0.00 $5.02 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$5.02Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customer andIn-transitInventoryRequirements(Weeks)Supplier,Customer and Intransit InventoryRequirements(Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3 PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000Packaging Cost for Fasteners included infastener piece price.No other packaging costs required."S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 10 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 1300Manufacturing Assumption and Quote SummaryAPPENDIX G.1-13, (6of6)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:OEM Assembly of Additional or Revised Lubrication Components to EnginePart Number:1300-N0101-00Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotal Mark-up Cost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000File:13 Lubrication Subsystem 032309.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-13, 11 of 11Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 14Cooling SubsystemCase Study #0101MAQS WorksheetsFile:14 Cooling System 033109.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-14, 1 of 9Pump-Aux. Coolant 1401 R5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-14 (1of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Pump- Auxiliary Coolant, ElectricPart Number:1401-N0101-02Weekly Component Volume: Packaging Specification:Returnable PackagingComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Charge Impeller Assembly 1401-N0101-02-3-11Magnetize Impeller AssemblyT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, MC, Base240 1 1 10.000$0.00 $35.51 $30.00 $30.00$0.00$0.15 $0.13 $0.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $0.272A Pump-Auxiliary Coolant Final Assembly 1401-N0101-021Final AssemblyT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, MC, Base240 2 1 90.000$0.00 $35.51 $30.00 $270.00$0.00$0.30 $1.13 $1.42 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.42 $1.42INTENTIONAL BLANK SPACE0##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.003A Pump-Auxiliary Coolant, Electric Subassembly 1401-N0101-00 (New P/N )1Assemble pump to bracket andhoses to pump.T1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base200 4 1 40.000$0.00 $35.51 $15.00 $60.00$0.00$0.71 $0.30 $1.01 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.01 $1.010##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - High Impact Item (Full Cost Mapping)1A Motor Housing Assembly 1401-N0101-02-1-11Injection Mold Housing w.TerminalsT1 Assembly, Mark-up Applied@ Bottom.PPS-GF40, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS360 0.5 1 20.110$6.02 $43.52 $150.01 $300.02 $0.66 $0.06 $0.83 $1.56 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.56 $1.562A End Cap Motor close out 1401-N0101-02-1-21Injection Mold Housing w.TerminalsT1 Assembly, Mark-up Applied@ Bottom.PPS-GF35-MF30, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS769 0.5 1 10.025$3.86 $43.52 $150.01 $150.01 $0.10 $0.03 $0.20 $0.32 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.32 $0.323A Housing Impellor Cavity 1401-N0101-02-2-11Injection Mold Housing w.TerminalsT1 Assembly, Mark-up Applied@ Bottom.PPS-GF35-MF30, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS626 0.5 1 10.094$3.86 $43.52 $150.01 $150.01 $0.36 $0.03 $0.24 $0.64 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.64 $0.644A Impellor Water Pump 1401-N0101-02-3-1-11Injection Mold Housing w.TerminalsT1 Assembly, Mark-up Applied@ Bottom.PPS-GF40, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS333 0.5 1 1.50.100$6.02 $43.52 $150.01 $225.02 $0.60 $0.07 $0.68 $1.34 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.34 $1.34INTENTIONAL BLANK SPACE0##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.001ABracket Subassembly - Auxiliary Pump to OilFilter/Cooler Ass'y1475-N0101-01-031Progressive Die BlankT1 Assembly, Mark-up Applied@ Bottom.LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC600 0.5 1 10.808$0.45 $42.18 $100.10 $100.10 $0.36 $0.04 $0.17 $0.57 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.57 $0.571BBracket Subassembly - Auxiliary Pump to OilFilter/Cooler Ass'y1475-N0101-01-021Stage Tooling (3 Stage)T1 Assembly, Mark-up Applied@ Bottom.Not Applicable Cut/Punch/Forming Operator Stamp/Form,SMS, LMC240 1 1 10.000$0.00 $42.18 $100.10 $100.10$0.00$0.18 $0.42 $0.59 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.59 $0.591CBracket Subassembly - Auxiliary Pump to OilFilter/Cooler Ass'y1475-N0101-01-011Apply CoatingT2/T3 Plate/Finish Mech., SSLCPowder Coat Plating/Coating Operator Plate/Finish, SMS, LMC720 1 1 10.010$20.00 $55.17 $100.17 $100.17 $0.20 $0.08 $0.14 $0.42 0.30%6.00% 4.00% 0.00% 10.30% $0.04 $0.46 $0.46Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Terminals 1401-N0101-02-711Terminals Tin Plate S$0.00$0.09$0.00 $0.092A O-ring - Motor Housing to Impeller Housing 1401-N0101-02-721Silicone S$0.00$0.04$0.00 $0.043A AlNiCo Magnets 1401-N0101-02-734(Uncharged, Approx 10x20x2.5) S$0.00$0.45$0.00 $1.804A Motor Winding Assembly 1401-N0101-02-1-1-31S$0.00$4.50$0.00 $4.505A PCB Motor Control Assembly 1401-N0101-02-1-1-21S$0.00$5.00$0.00 $5.006A E-Clip1401-N0101-02-51S$0.00$0.02$0.00 $0.027A Heat Sink 1401-N0101-02-61S$0.00$0.05$0.00 $0.058A Screw Impellor cavity to motor housing 1401-N0101-02-2-24S$0.00$0.02$0.00 $0.089A Bolt pump to bracket 1401-N0101-02-023S$0.00$0.01$0.00 $0.0310A Wire Harness Retention Clips NA2Required for O2 Sensor, ThusNo Cost Impact.S$0.00$0.00$0.00 $0.0011AHose Assembly - Oil Filer/Cooler Ass'y toAuxiliary Pump1470-N0101-041SAC$2.07$2.07$0.00 $2.0712A Hose Assembly - Auxiliary Pump to Turbo 1470-N0101-031SAC$3.81$3.81$0.00 $3.81Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$25.67T1 or OEM Total Manufacturing Cost:$19.78 $1.63 $4.22 $25.63 $0.00 $0.02 $0.02 $0.00 $0.04 $25.67T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%(SAC)&T1 or OEM Mark-Up Values:(5.88)----- ----- -----$0.18 $1.80 $2.05 $1.03 $5.06Base Cost Impact to Vehicle:$13.90 $1.63 $4.22 $19.75 $0.18 $1.82 $2.07 $1.03 $5.10 $24.85 $0 $0Packaging Cost:$0.06Net Cost Impact to Vehicle:$24.919,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENT"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-14, 2 of 9Form Author: G. Kolwich(248)373-6000 Ext. 2411Pump-Aux. Coolant 1401 R5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-14 (1of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Pump- Auxiliary Coolant, ElectricPart Number:1401-N0101-02Weekly Component Volume: Packaging Specification:Returnable PackagingComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTFull QuoteModificationDifferential Quote (Quote Summary includesCost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.059 $118,2030.00%2,250,000 605.00%$500236243657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.059PACKAGING CALCULATIONS:Packaging Type: Option 1 w. Expendable DividersPart Size: 340X130X90Parts/Layer:3X9Number of Layers: 9File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-14, 3 of 9Form Author: G. Kolwich(248)373-6000 Ext. 2411Hose,Oil Cool. - Aux Pump 1470DManufacturing Assumption and Quote SummaryAPPENDIX G.1-14 (2of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Hose Assembly - Oil Filer/Cooler Ass'y to AuxiliaryPumpPart Number:1470-N0101-04Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Hose - Oil Filter/Cooler Ass'y to Auxiliary Pump 1470-N0101-04-11Extrude & Shape Hose SSBR-Fiber Rein.,ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC273 1.50.127$1.85 $54.35 $100.04 $0.23 $0.30 $0.37 $0.900.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.90 $0.902A Hose - Oil Filter/Cooler Ass'y to Auxiliary Pump 1470-N0101-04-11Assemble Sheathing and GlueClampsS Purchased Parts General AssemblyMech Assembly, LC,Base240 2$0.62$1.00 $35.51 $15.00 $0.62 $0.30 $0.06 $0.980.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.98 $0.980##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Sheath Hose Protection (Aux-Filter) 1470-N0101-04-21Nylon B2B$0.00$0.28$0.28 $0.002A Hose Clamp 1470-N0101-03-12Steel- Zinc Phosphate B2B$0.00$0.17$0.34 $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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$1.88T1 or OEM Total Manufacturing Cost:$0.85 $0.59 $0.43 $1.88 $0.00 $0.00 $0.00 $0.00 $0.00 $1.88T1 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 $0.19Base Cost Impact to Vehicle:$0.85 $0.59 $0.43 $1.88 $0.01 $0.11 $0.08 $0.00 $0.19 $2.07 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$2.07Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%2,250,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000Packaging Options: Shipped w. Aux.Pump, No Packaging Costs Required"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-14, 4 of 9Form Author: G. Kolwich(248)373-6000 Ext. 2411Hose Ass'y-Turbo-Aux Pump 1470CManufacturing Assumption and Quote SummaryAPPENDIX G.1-14 (3of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Hose Assembly - Auxiliary Pump to TurboPart Number:1470-N0101-03Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Fitting Hose End 1306-N0101-01-11-51Cold Headed Tubing S LC-Steel-1215, Tubing Forging Operator Cold Forge, LMC720 0.50.092$0.62 $38.52 $100.09 $0.06 $0.03 $0.14 $0.220.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.22 $0.222A Fitting Tube End 1370-N0101-02-41CNC Machine S LC-Steel-1215, Bar CNC Operator CNC Turning, MHC240 0.50.270$0.62 $35.70 $125.00 $0.17 $0.07 $0.52 $0.760.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.76 $0.763A Tube 1306-N0101-01-11-5-21Cut to size and form S LC-Steel-1215, Tubing Cut/Punch/Forming OperatorHydro/CNC Form,SMS, LMC360 0.50.030$0.62 $42.18 $100.12 $0.02 $0.06 $0.28 $0.360.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.36 $0.364A Tube Assembly - Banjo Joint for Turbo 1470-N0101-03-031Assemble, Braze and Plate S Not Applicable General Assembly Mech. Assembly, LC257 20.000$0.00 $35.51 $100.19$0.00$0.28 $0.39 $0.670.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.67 $0.675A Hose Assembly - Auxiliary Pump to Turbo 1470-N0101-03-021Extrude & Shape Hose SSBR-Fiber Rein.,ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC581 1.50.091$1.85 $54.35 $100.04 $0.17 $0.14 $0.17 $0.480.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.48 $0.486A Hose Assembly - Auxiliary Pump to Turbo 1470-N0101-03-011Overmold Banjo Tube to Hose S Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS360 10.007$1.74 $43.52 $100.01 $0.01 $0.12 $0.28 $0.410.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.41 $0.417A Hose Assembly - Auxiliary Pump to Turbo 1470-N0101-031Assemble Sheathing andGlue ClampS Purchased Parts General AssemblyMech Assembly, LC,Base200 1$0.30$1.00 $35.51 $15.00 $0.30 $0.18 $0.08 $0.550.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.55 $0.550##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Hose Clamp 1470-N0101-03-11Steel- Zinc Phosphate B3C$0.00$0.17$0.17 $0.002A Sheath Hose protection (Turbo) 1470-N0101-03-21B3C$0.00$0.13$0.13 $0.00$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$3.45T1 or OEM Total Manufacturing Cost:$0.72 $0.87 $1.85 $3.45 $0.00 $0.00 $0.00 $0.00 $0.00 $3.45T1 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 $0.21 $0.14 $0.00 $0.36Base Cost Impact to Vehicle:$0.72 $0.87 $1.85 $3.45 $0.01 $0.21 $0.14 $0.00 $0.36 $3.81 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$3.81109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENT"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-14, 5 of 9Form Author: G. Kolwich(248)373-6000 Ext. 2411Hose Ass'y-Turbo-Aux Pump 1470CManufacturing Assumption and Quote SummaryAPPENDIX G.1-14 (3of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Hose Assembly - Auxiliary Pump to TurboPart Number:1470-N0101-03Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTPackaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000Packaging Options: Shipped w. Aux.Pump, No Packaging Costs RequiredFile:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-14, 6 of 9Form Author: G. Kolwich(248)373-6000 Ext. 2411Hose Ass'y Turbo-Thermo, 1470Manufacturing Assumption and Quote SummaryAPPENDIX G.1-14, (4of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Hose Assembly - Turbo Assembly to Thermostat/Coolant ValvePart Number:1470-N0101-02Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotal Mark-up Cost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Tube Assembly Prefabricated 1470-N0101-02-04-011Assemble, Braze S Not Applicable General AssemblyMech Assembly,HC, Base240 10.000$0.00 $35.51 $45.00$0.00$0.15 $0.19 $0.340.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.34 $0.342A Tube Assembly Prefabricated 1470-N0101-02-04-021Projection Weld Brkt S Not Applicable General AssemblyMech Assembly, LC,Base240 10.000$0.00 $35.51 $15.00$0.00$0.15 $0.06 $0.210.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.21 $0.213A Tube Assembly Prefabricated 1470-N0101-02-04-021Plating SGeneral UnderhoodPlatingPlating/Coating Operator Plate/Finish, MLS, LMC720 10.001$15.00 $55.17 $150.17 $0.02 $0.08 $0.21 $0.300.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.30 $0.304AHose Assembly - Turbo Assembly toThermostat/Coolant Valve1470-N0101-021Assemble SBR Tube with twohose clampsS Not Applicable General AssemblyMech Assembly, LC,Base240 20.000$0.00 $35.51 $15.00$0.00$0.30 $0.06 $0.360.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.36 $0.360##### 00.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A0.00% 0.00% 0.00% 0.00%0.00% #N/A #N/A $0.00Purchase Part - High Impact Item (Full Cost Mapping)1A Fitting Tube End 1370-N0101-02-41CNC Machine S LC-Steel-1215, Bar CNC Operator CNC Turning, MHC240 0.50.270$0.62 $35.70 $125.00 $0.17 $0.07 $0.52 $0.760.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.76 $0.762A Bracket Tube Attachment 1470-N0101-02-4-41Stamping S LC-Steel-1000S, Coil Cut/Punch/Forming OperatorStamp/Form, SMS,LMC600 0.50.233$0.45 $42.18 $100.10 $0.10 $0.04 $0.17 $0.310.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.31 $0.313A Preformed Tube 10mm OD 1470-N0101-02-4-11Cut to size and form S LC-Steel-1215, Tubing Cut/Punch/Forming OperatorHydro/CNC Form,SMS, LMC360 0.50.150$0.62 $42.18 $100.12 $0.09 $0.06 $0.28 $0.430.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.43 $0.434A Preformed Tube 14mm OD 1470-N0101-02-4-21Cut to size and form S LC-Steel-1215, Tubing Cut/Punch/Forming OperatorHydro/CNC Form,SMS, LMC240 10.060$0.62 $42.18 $100.12 $0.04 $0.18 $0.42 $0.630.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.63 $0.635A Hose - Oil Filter/Cooler Ass'y to Auxiliary Pump 1470-N0101-04-11Extrude & Shape Hose SSBR-Fiber Rein.,ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC933 1.50.055$1.85 $54.35 $100.04 $0.10 $0.09 $0.11 $0.300.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.30 $0.30Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchase Price/UnitPurchase PriceNet, PIAPurchasePrice Net, EndItem1A Hose Clamp small ID 1470-N0101-02-21S$0.00$0.24$0.00 $0.242A Hose Clamp large ID 1470-N0101-02-31S$0.00$0.26$0.00 $0.260$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotal Mark-up$4.13T1 or OEM Total Manufacturing Cost:$1.02 $1.10 $2.01 $4.13 $0.00 $0.00 $0.00 $0.00 $0.00 $4.13T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.03% 6.00% 4.00% 0.00% 10.03%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.25 $0.17 $0.00 $0.41Base Cost Impact to Vehicle:$1.02 $1.10 $2.01 $4.13 $0.00 $0.25 $0.17 $0.00 $0.41 $4.55 $0 $0Packaging Cost:$0.04Net Cost Impact to Vehicle:$4.59TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000"S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-14, 7 of 9Form Author: G. Kolwich(248)373-6000 Ext. 2411Hose Ass'y Turbo-Thermo, 1470Manufacturing Assumption and Quote SummaryAPPENDIX G.1-14, (4of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Hose Assembly - Turbo Assembly to Thermostat/Coolant ValvePart Number:1470-N0101-02Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotal Mark-up Cost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customer andIn-transitInventoryRequirements(Weeks)Supplier,Customer and Intransit InventoryRequirements(Parts)Rack/Pallet Investment Amortization:$0.015 $30,3950.00%2,250,000 605.00%$200152378657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3 PadsPallet/RackExpendable Packaging in Piece Cost:$0.03$1.00 10 $3.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.042Pallet Option #1 w. Expendable Tier PadsPart Size 400x80x90Parts/Layer = 3x14Number of Layers = 9File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-14, 8 of 9Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 1400Manufacturing Assumption and Quote SummaryAPPENDIX G.1-14, (5of5)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:OEM Assembly of Additional or Revised Assembly Components to EnginePart Number:1400-N0101-00Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Assembly Pump-Aux. Coolant Subassembly 1401-N0101-02+ Subs1Mount Auxiliary Pump to OilCooler/Filter (2 Screws), MakeElectrical ConnectionConstrain wire in ClipsOEM Not Applicable General Assembly-OEM Engine Assembly, OEM129 10.000$0.00 $83.31 $150.21$0.00$0.65 $1.17 $1.820.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.82 $1.822AHose Assembly, Turbo -Aux Pump and HoseAss'y- Turbo - Thermostat Valve1470-N0101-02/031Install and run Banjo bolt (x2)@ turbo.OEM Not Applicable General Assembly-OEM Engine Assembly, OEM129 10.000$0.00 $83.31 $150.21$0.00$0.65 $1.17 $1.820.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.82 $1.823AHose, Oil Cooler to Aux Pump and Hose Ass'yTurbo Thermostat Valve to Thermostat Valve1470-N0101-02/041Press on Tubes and releaseHose ClampsOEM Not Applicable General Assembly-OEM Engine Assembly, OEM129 10.000$0.00 $83.31 $150.21$0.00$0.65 $1.17 $1.820.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.82 $1.824AHose Assembly - Turbo Assembly toThermostat/Coolant Valve1470-N0101-020Run fastener to secure HoseAssembly Bracket to EngineOEM Not Applicable General Assembly-OEM Engine Assembly, OEM300 10.000$0.00 $83.31 $150.21$0.00$0.28 $0.50 $0.780.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.78 $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Bolt-Hose, coolant Inlet and Outlet @ Turbo 1480-N0101-062Banjo Bolts S$0.00$0.24$0.00 $0.482AWasher banjo Bolt-Hose, coolant Inlet and Outlet @1480-N0101-134Banjo Washers S$0.00$0.02$0.00 $0.083ABolt-Hose Bracket, coolant Inlet and Outlet @Turbo1480-N0101-141S$0.00$0.12$0.00 $0.124A Bolt Aux pump bracket to oil cooler 1480-N0101-073S$0.00$0.02$0.00 $0.065A Pump- Auxiliary Coolant, Electric 1401-N0101-021SAC$24.91$24.91$0.00 $24.916AHose Assembly - Turbo Assembly toThermostat/Coolant Valve1470-N0101-021SAC$4.59$4.59$0.00 $4.59Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$35.68T1 or OEM Total Manufacturing Cost:$30.23 $1.94 $3.50 $35.68 $0.00 $0.00 $0.00 $0.00 $0.00 $35.68T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:(29.49)----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$0.74 $1.94 $3.50 $6.19 $0.00 $0.00 $0.00 $0.00 $0.00 $6.19 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$6.19Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000TOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable Separators109,57447450,0001450,000Packaging Cost for Fasteners included infastener piece price.No other packaging costs required."S"=Indicates Component is Supplied directly to T1 or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:14 Cooling System 033109.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-14, 9 of 9Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 15Air Induction Charging SubsystemCase Study #0101MAQS WorksheetsFile:15 Air Induction Charging System 040109A.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-15, 1 of 16Turbo Assembly 1501 Rev 5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15(1of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Turbo Charging AssemblyPart Number:1501-N0101-01Weekly Component Volume: Packaging Specification:ReturnableComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Block Turbo shaft support - cooling & lub 1201-N0101-01-101Subassembly Center SupportBlockT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, MC, Base177 4 1 80.000$0.00 $35.51 $30.00 $240.00$0.00$0.80 $1.35 $2.15 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.15 $2.152A Housing Turbo Exhaust 1201-N0101-01-091Subassembly Exhaust HousingT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base180 2 1 30.000$0.00 $35.51 $15.00 $45.00$0.00$0.39 $0.25 $0.64 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.64 $0.643A Final Assembly Line 1501-N0101-011Final Product Assembly & TestT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base180 11 1 130.000$0.00 $35.51 $15.00 $195.00$0.00$2.17 $1.08 $3.25 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $3.25 $3.254A Turbine Shaft Assembly - Welded 1201-N0101-01-01-24-011Electron Beam Weld TurbineImpeller to Shaft and GrindProfileT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, MC, Base180 1 1 20.000$0.00 $35.51 $30.00 $60.00$0.00$0.20 $0.33 $0.53 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.53 $0.535ATurbo Assembly Center Housing RotatingAssembly (CHRA) Balancing1201-N0101-01-01-241High Speed Dynamic BalancingT1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, HC, Base180 4.5 3 10.000$0.00 $35.51 $45.00 $135.00$0.00$0.89 $0.75 $1.64 10.00% 0.00% 0.00% 0.00% 10.00% $0.16 $1.80 $1.80Purchase Part - High Impact Item (Full Cost Mapping)1A Housing Turbo Intake Casting 1201-N0101-01-07-01-21Cast Intake Housing T2/T3 Sand Cast, MSMC Aluminum-A319-T5, Cast Mold/Cast/Sinter Operator Sand Cast, HMC120 6 1 12.200$1.15 $43.52 $150.07 $150.07 $2.53 $2.18 $1.25 $5.96 5.00% 6.50% 6.00% 1.00% 18.50% $1.10 $7.06 $7.061B Housing Turbo Intake Casting 1201-N0101-01-07-01-11T5 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC125 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.37 $0.80 $1.17 0.50% 6.50% 6.00% 1.00% 14.00% $0.16 $1.34$1.341C Housing Turbo Intake Casting 1201-N0101-01-07-011Machine Intake Housing T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MHC119 3 7 10.000$0.00 $35.70 $45.00 $315.00$0.00$0.90 $2.64 $3.53 0.50% 6.50% 6.00% 1.00% 14.00% $0.49 $4.03$4.032A Block Center Bearing Support 1201-N0101-01-30-021Sand Casting T2/T3 Sand Cast, MSMC SiMo Ductile Iron,Cast Mold/Cast/Sinter Operator Sand Cast, HMC160 9 1 13.500$0.60 $43.52 $150.07 $150.07 $2.10 $2.45 $0.94 $5.49 5.00% 6.50% 6.00% 1.00% 18.50% $1.01 $6.50 $6.502B Block Center Bearing Support 1201-N0101-01-30-011T5 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC167 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.28 $0.60 $0.88 0.50% 6.50% 6.00% 1.00% 14.00% $0.12 $1.00$1.002C Block Center Bearing Support 1201-N0101-01-301Critical Faces Machine T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MHC122 4 8 10.000$0.00 $35.70 $45.00 $360.00$0.00$1.18 $2.96 $4.14 0.50% 6.50% 6.00% 1.00% 14.00% $0.58 $4.72$4.723A Housing Turbo Exhaust 1201-N0101-01-09-01-021Sand Casting T2/T3 Sand Cast, MSMC NiResist Iron, D5S, Cast Mold/Cast/Sinter Operator Sand Cast, HMC120 6 1 16.890$3.50 $43.52 $150.07 $150.07 $24.12 $2.18 $1.25 $27.54 5.00% 6.50% 6.00% 1.00% 18.50% $5.10 $32.64 $32.643B Housing Turbo Intake Casting 1201-N0101-01-09-01-011T5 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC114 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.41 $0.88 $1.28 0.50% 6.50% 6.00% 1.00% 14.00% $0.18 $1.46$1.463C Housing Turbo Exhaust 1201-N0101-01-09-011Machine Casting T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MHC, PREM.114 3 6 10.000$0.00 $35.70 $55.00 $330.00$0.00$0.94 $2.90 $3.84 0.50% 6.50% 6.00% 1.00% 14.00% $0.54 $4.38$4.384A Support Plate intake side 1201-N0101-01-26-021Diecasting T2/T3 Diecast, SSLC Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC275 1 1 10.421$1.10 $43.52 $100.05 $100.05 $0.46 $0.16 $0.36 $0.99 5.00% 6.00% 4.00% 0.00% 15.00% $0.15 $1.13 $1.134B Support Plate intake side 1201-N0101-01-26-011T5 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC267 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.17 $0.38 $0.55 0.50% 6.50% 6.00% 1.00% 14.00% $0.08 $0.63$0.634C Support Plate intake side 1201-N0101-01-261Machine Casting T2/T3 CNC Turning, SSLC Not Applicable CNC Operator CNC Turning, MC129 1 2 10.000$0.00 $35.70 $45.00 $90.00$0.00$0.28 $0.70 $0.98 0.30% 6.00% 4.00% 0.00% 10.30% $0.10 $1.08$1.085A Heat Shield Exhaust shaft seal 1201-N0101-01-291Stamp T2/T3 Stamp/Form, SSLC Inconel-713C, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC621 0.5 1 10.029$6.00 $42.18 $100.10 $100.10 $0.17 $0.03 $0.16 $0.37 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.41 $0.416A Anti-rotate plate - bushing 1201-N0101-01-341Stamp T2/T3 Stamp/Form, SSLC SPR-Steel, Coil Cut/Punch/Forming Operator Stamp/Form, SMS, LMC720 0.5 1 10.005$0.65 $42.18 $100.10 $100.10 $0.00 $0.03 $0.14 $0.17 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.19 $0.197A Plate Brass Oil Diverter 1201-N0101-01-19-11Stamp Part T2/T3 Stamp/Form, SSLC Bronze-89320, Bar Cut/Punch/Forming Operator Stamp/Form, SMS, LMC679 0.5 1 10.027$2.56 $42.18 $100.10 $100.10 $0.07 $0.03 $0.15 $0.25 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.27 $0.277B Plate Brass Oil Diverter 1201-N0101-01-191Machine Oil Pass Through T2/T3 CNC Milling, MSMC NotApplicable CNC Operator CNC Machining, LMC257 0.25 1 20.000$0.00 $35.70 $25.00 $50.00$0.00$0.03 $0.19 $0.23 0.50% 6.50% 6.00% 1.00% 14.00% $0.03 $0.26$0.268A Bushing - Turbine Shaft 1201-N0101-01-321Screw Machine T2/T3 CNC Turning, MSMC Bronze-89320, Bar CNC Operator S-CNC Turning, HC117 1 2.5 10.070$2.56 $35.70 $85.00 $212.50 $0.18 $0.31 $1.82 $2.30 0.50% 6.50% 6.00% 1.00% 14.00% $0.32 $2.63 $2.639A Seal Carrier support plate mount 1201-N0101-01-27-011Screw Machine T2/T3 CNC Turning, MSMCA-Steel-4140, BarCNC Operator S-CNC Turning, LC160 1 2 10.040$0.78 $35.70 $35.00 $70.00 $0.03 $0.22 $0.44 $0.69 0.50% 6.50% 6.00% 1.00% 14.00% $0.10 $0.79 $0.7910A Valve Exhaust Dump 1201-N0101-01-09-01-05-021Investment Cast T2/T3 Invest. Cast, LSHC Nickel AlloyGen, Cast Mold/Cast/Sinter Operator Invest. Cast, HMC120 7 1 10.150$5.00 $43.52 $150.08 $150.08 $0.75 $2.54 $1.25 $4.54 5.00% 7.00% 8.00% 2.00% 22.00% $1.00 $5.54 $5.5410B Valve Exhaust Dump 1201-N0101-01-09-01-05-011Heat Treat T2/T3 Heat Treat, MSMC Not Applicable HeatTreat Operator Heat Treat, MLS, LMC118 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.39 $0.84 $1.24 0.50% 6.50% 6.00% 1.00% 14.00% $0.17 $1.41$1.4110C Valve Exhaust Dump 1201-N0101-01-09-01-051Machine T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, LMC, PREM.180 0.5 1 10.000$0.00 $35.70 $35.00 $35.00$0.00$0.10 $0.19 $0.29 0.50% 6.50% 6.00% 1.00% 14.00% $0.04 $0.33$0.3311A Arm - Valve to Shaft 1201-N0101-01-09-01-06-021Investment Cast T2/T3 Invest. Cast, LSHC Nickel AlloyGen, Cast Mold/Cast/Sinter Operator Invest. Cast, HMC120 7 1 10.153$5.00 $43.52 $150.08 $150.08 $0.77 $2.54 $1.25 $4.55 5.00% 7.00% 8.00% 2.00% 22.00% $1.00 $5.56 $5.5611B Arm - Valve to Shaft 1201-N0101-01-09-01-06-011Heat Treat T2/T3 Heat Treat, MSMC Not Applicable HeatTreat Operator Heat Treat, MLS, LMC118 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.39 $0.84 $1.24 0.50% 6.50% 6.00% 1.00% 14.00% $0.17 $1.41$1.4111C Arm - Valve to Shaft 1201-N0101-01-09-01-061Machine T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, LMC, PREM.120 0.5 1 10.000$0.00 $35.70 $35.00 $35.00$0.00$0.15 $0.29 $0.44 0.50% 6.50% 6.00% 1.00% 14.00% $0.06 $0.50$0.5012A Block control rod attachment 1201-N0101-01-09-01-101Permanent Cast T2/T3 Perm. Cast, SSLC S-Steel-310, Cast Mold/Cast/Sinter Operator Perm. Cast, LMC960 3 1 10.042$2.40 $43.52 $100.06 $100.06 $0.10 $0.14 $0.10 $0.34 5.00% 6.00% 4.00% 0.00% 15.00% $0.05 $0.39 $0.3912B Block control rod attachment 1201-N0101-01-09-01-101Machine T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, LMC, PREM.200 0.5 1 10.000$0.00 $35.70 $35.00 $35.00$0.00$0.09 $0.18 $0.26 0.50% 6.50% 6.00% 1.00% 14.00% $0.04 $0.30$0.3013A Arm Dump Valve Control 1201-N0101-01-09-01-081Permanent Cast T2/T3 Perm. Cast, SSLC S-Steel-310, Cast Mold/Cast/Sinter Operator Perm. Cast, LMC960 3 1 10.050$2.40 $43.52 $100.06 $100.06 $0.12 $0.14 $0.10 $0.36 5.00% 6.00% 4.00% 0.00% 15.00% $0.05 $0.41 $0.4114A Impeller Intake 1201-N0101-01-16-031Rubber/Plaster Mold T2/T3 Invest. Cast, LSHC Aluminum-356-T6, Cast Mold/Cast/Sinter Operator Invest. Cast,HMC180 5 1.25 10.064$1.20 $43.52 $150.08 $187.60 $0.08 $1.21 $1.04 $2.33 25.00%7.00% 8.00% 2.00% 42.00% $0.98 $3.31 $3.3114B Impeller Intake 1201-N0101-01-16-021T6 Heat Treat T2/T3 Heat Treat, MSMC Not Applicable Heat Treat Operator Heat Treat, MLS, LMC174 1 1.5 10.000$0.00 $46.52 $100.00 $150.00$0.00$0.27 $0.86 $1.13 20.00% 6.50% 6.00% 1.00% 33.50% $0.38 $1.51 $1.5114C Impeller Intake 1201-N0101-01-16-011Machine T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, MC164 1 2.5 10.000$0.00 $35.70 $45.00 $112.50$0.00$0.22 $0.69 $0.91 20.00% 6.50% 6.00% 1.00% 33.50% $0.30 $1.21 $1.2114D Impeller Intake 1201-N0101-01-1612 Plane Dynamic Balance T2/T3 CNC Turning, MSMC NotApplicable Precision Assembly Balancing, SMS, MHC180 4.5 3 10.000$0.00 $25.74 $45.00 $135.00$0.00$0.64 $0.75 $1.39 20.00% 6.50% 6.00% 1.00% 33.50% $0.47 $1.86 $1.8615A Turbine Wheel 1201-N0101-01-01-24-051Investment Cast T2/T3 Invest. Cast, LSHC Inconel-713,Cast Mold/Cast/Sinter Operator Invest. Cast, HMC180 9 1.5 10.075$6.00 $43.52 $150.08 $225.12 $0.45 $2.18 $1.25 $3.88 25.00%7.00% 8.00% 2.00% 42.00% $1.63 $5.51 $5.5115B Turbine Wheel 1201-N0101-01-01-24-041Heat Treat T2/T3 Heat Treat, MSMC Not Applicable HeatTreat Operator Heat Treat, MLS, LMC178 1 1.5 10.000$0.00 $46.52 $100.00 $150.00$0.00$0.26 $0.84 $1.11 20.00% 6.50% 6.00% 1.00% 33.50% $0.37 $1.48 $1.4815C Turbine Wheel 1201-N0101-01-01-24-031Machine T2/T3 CNC Turning, MSMC Not Applicable CNC Operator CNC Turning, MC180 0.5 1 10.000$0.00 $35.70 $45.00 $45.00$0.00$0.10 $0.25 $0.35 20.00% 6.50% 6.00% 1.00% 33.50% $0.12 $0.47 $0.4715D Turbine Wheel 1201-N0101-01-01-24-0212 Plane Dynamic Balance T2/T3 CNC Turning, MSMC NotApplicable Precision Assembly Balancing, SMS, MHC180 4.5 3 10.000$0.00 $25.74 $45.00 $135.00$0.00$0.64 $0.75 $1.39 20.00% 6.50% 6.00% 1.00% 33.50% $0.47 $1.86 $1.8616A Turnbine Shaft 1201-N0101-01-01-24-03-011Machine & Grind Shaft T2/T3 CNC Turning, MSMCA-Steel-4140, BarCNC Operator S-CNC Turning, MC176 1 2.5 10.255$0.78 $35.70 $55.00 $137.50 $0.20 $0.20 $0.78 $1.18 10.00% 6.50% 6.00% 1.00% 23.50% $0.28 $1.46 $1.469,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTFull QuoteModification QuoteDifferential Quote (Quote Summary includesImpeller Wheels, 5%Casting fallout, 10%Wheel BalanceFallout and 10% FinalAssembly BalanceFalloutFile:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3APPENDIX G.1-15, 2 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Turbo Assembly 1501 Rev 5Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15(1of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Turbo Charging AssemblyPart Number:1501-N0101-01Weekly Component Volume: Packaging Specification:ReturnableComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTFull QuoteModification QuoteDifferential Quote (Quote Summary includes16B Turnbine Shaft 1201-N0101-01-01-24-031Heat Treat T2/T3 Heat Treat, MSMC Not Applicable HeatTreat Operator Heat Treat, MLS, LMC250 1 1 10.000$0.00 $46.52 $100.00 $100.00$0.00$0.19 $0.40 $0.59 10.00% 6.50% 6.00% 1.00% 23.50% $0.14 $0.72 $0.72Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Seal Shaft exhaust end 1201-N0101-01-251(M2 Tool Steel & Inconel) S$0.00$1.00$0.00 $1.002A Plug Threaded 1201-N0101-01-30-032S$0.00$0.04$0.00 $0.083A Sleeve Shaft Bushing 1201-N0101-01-30-021S$0.00$0.03$0.00 $0.034A Snap Ring - Bearing retainer 1201-N0101-01-311S$0.00$0.02$0.00 $0.025a C-Clip - Bushing Retainer 1201-N0101-01-331S$0.00$0.01$0.00 $0.016A O-Ring Inner ID of support plate to block 1201-N0101-01-211S$0.00$0.18$0.00 $0.187A Spacer Oil Diverter Plates 1201-N0101-01-201S$0.00$0.06$0.00 $0.068A Seal - Shaft Support Plate to seal carrier 1201-N0101-01-281S$0.00$0.02$0.00 $0.029A Nut turbine Shaft 1201-N0101-01-151S$0.00$0.08$0.00 $0.0810A O-Ring Intake Housing to block seal 1201-N0101-01-141S$0.00$0.08$0.00 $0.0811A Bolt Intake Housing to Shaft Housing 1201-N0101-01-044S$0.00$0.07$0.00 $0.3012A Pin Housing to Center Block Locating 1201-N0101-01-09-01-131S$0.00$0.01$0.00 $0.0113A Bushing Dump Valve Shaft 1201-N0101-01-09-01-091(Specialized Alloy or Nitrided) S$0.00$0.86$0.00 $0.8614A Washer - Valve Retainer 1201-N0101-01-09-01-071Stainless S$0.00$0.17$0.00 $0.1715A Washer Block retainer 1201-N0101-01-09-01-111Steel S$0.00$0.03$0.00 $0.0316A Stud Turbo to Exhaust Manifold 1201-N0101-01-114Stainless (A286) S$0.00$0.27$0.00 $1.0717A Stud - Catalytic Coverter 1280-N0101-073Stainless (A286) S$0.00$0.37$0.00 $1.1018A Clamp Exhaust housing to shaft block 1201-N0101-01-081Stainless S$0.00$1.24$0.00 $1.2419A Nut Saddle Clamp 1201-N0101-01-131Stainless S$0.00$0.03$0.00 $0.0320A Solenoid Intake Bypass 1201-N0101-01-051S$0.00$6.00$0.00 $6.0021A Gasket Intake Housing Solenoid 1201-N0101-01-121S$0.00$0.08$0.00 $0.0822A Bolt Solenoid to Intake Housing 1201-N0101-01-063S$0.00$0.06$0.00 $0.1823A Diaphram Exhaust dump valve 1201-N0101-01-011S$0.00$5.00$0.00 $5.0024A Nut Exhaust Diaphram Shaft 1201-N0101-01-022S$0.00$0.01$0.00 $0.0125A Nut Diaphram to Intake Housing 1201-N0101-01-032S$0.00$0.01$0.00 $0.0226A Gasket - Turbo Inlet to Exhaust Manifold 1285-N0101-011S$0.00$1.60$0.00 $1.6027A Nut - Turbo to exhaust Manifold 1280-N0101-104S$0.00$0.09$0.00 $0.3528A Tag ID 1201-N0101-01-07-021S$0.00$0.10$0.00 $0.1029A Rivet ID Tag 1201-N0101-01-07-031S$0.00$0.01$0.00 $0.010$0.00$0.00$0.00 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$126.77T1 or OEM Total Manufacturing Cost:$49.30 $26.79 $33.75 $109.84 $5.45 $5.38 $5.15 $0.94 $16.93$126.77T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.89 $8.87 $10.14 $5.07 $24.97Base Cost Impact to Vehicle:$49.30 $26.79 $33.75 $109.84 $6.34 $14.26 $15.29 $6.01 $41.90 $151.75 $0 $0Packaging Cost:$0.11Net Cost Impact to Vehicle:$151.85Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.108 $215,4260.00%2,250,000 605.00%$30071880657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.108PACKAGING CALCULATIONS:Packaging Type: Option #2Part Size: 300x200X190Parts/Layer: 4x5Number of Layers: 4"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3APPENDIX G.1-15, 3 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Cooler Assembly 1505Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15(2of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Cooler Assembly - Charged AirPart Number:1505-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotal Mark-up Cost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1B Tube with cooling fins 1505-N0101-01-1-15Insert Cooling Fins, Laserweld seem on Tube, PressureTest.S Not Applicable General Assembly Mech. Assembly, MC566 20.000$0.00 $35.51 $125.19$0.00$0.13 $0.22 $0.350.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.35 $1.732C Cooler Assembly - Charged Air Heat Exchanger 1505-N0101-01-01-021Assemble Tube Assemblies,Outer Fins, Top/Bottom Platesand Header Plates, Gasket &End CapsS Not Applicable General Assembly Mech. Assembly, MC116 50.000$0.00 $35.51 $125.19$0.00$1.53 $1.08 $2.610.00% 0.00% 0.00% 0.00%0.00% $0.00 $2.61 $2.61Purchase Part - High Impact Item (Full Cost Mapping)1A Tube1505-N0101-01-1-25Pre-Form & Cut to Length SAluminum-3003/4047A,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, MHC514 0.50.320$1.65 $42.18 $125.10 $0.53 $0.04 $0.24 $0.810.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.81 $4.062A Cooling Fins Inside Tube 1505-N0101-01-1-3-015Form and Cut to Length SAluminum-3003/4047A,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, MHC720 0.50.100$1.65 $42.18 $125.10 $0.17 $0.03 $0.17 $0.370.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.37 $1.843A Top/Bottom Plates 1505-N0101-01-1-42Form and Cut to Length SAluminum-3003/4047A,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, MHC720 0.50.110$1.65 $42.18 $125.10 $0.18 $0.03 $0.17 $0.380.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.38 $0.774A Cooling Fins Outer 1505-N0101-01-1-5--016Lance, Form, Cut to length SAluminum-3003/4047A,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, MHC720 0.50.140$1.65 $42.18 $125.10 $0.23 $0.03 $0.17 $0.430.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.43 $2.604B Header Plate 1505-N0101-01-1-6-012Pierce and Form SAluminum3003/4047B,CladdingCut/Punch/Forming OperatorStamp/Form, SMS, MHC529 0.250.130$2.10 $42.18 $125.10 $0.27 $0.02 $0.24 $0.530.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.53 $1.065AEnd Cap R Cooler Assembly - Charged Air HeatExchange1505-N0101-01-21Injection Mold S Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS655 0.50.254$1.54 $43.52 $100.01 $0.39 $0.03 $0.15 $0.580.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.58 $0.585BEnd Cap L Cooler Assembly - Charged Air HeatExchange1505-N0101-01-31Injection Mold S Nylon66-50GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS643 0.50.299$1.54 $43.52 $100.01 $0.46 $0.03 $0.16 $0.650.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.65 $0.65Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchase Price/UnitPurchase PriceNet, PIAPurchase PriceNet, End Item1A Gasket End Cap 1505-N0101-01-42S$0.00$0.15$0.00 $0.300$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotal Mark-up$16.20T1 or OEM Total Manufacturing Cost:$6.91 $2.85 $6.44 $16.20 $0.00 $0.00 $0.00 $0.00 $0.00 $16.20T1 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 $2.35Base Cost Impact to Vehicle:$6.91 $2.85 $6.44 $16.20 $0.08 $0.97 $0.97 $0.32 $2.35 $18.55 $0 $0Packaging Cost:$0.10Net Cost Impact to Vehicle:$18.65109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENT"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3APpendix G.1-15, 4 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Cooler Assembly 1505Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15(2of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Cooler Assembly - Charged AirPart Number:1505-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotal Mark-up Cost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTPackaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customer andIn-transitInventoryRequirements(Weeks)Supplier,Customer and Intransit InventoryRequirements(Parts)Rack/Pallet Investment Amortization:$0.096 $382,9790.00%4,500,000 605.00%$42091263657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3 PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.096File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3APpendix G.1-15, 5 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Ass'y-Waste Gate 1570AManufacturing Assumption and Quote SummaryAPPENDIX G.1-15(3of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Tube Assembly - Turbo Waste Gate Pneumatic ControlPart Number:1570-N0101-03Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Tube Reservoir to Solenoid 1770-N0101-03-11Assemble sheathing and glueon end connections.S Not Applicable General Assembly Mech. Assembly, LC180 10.000$0.00 $35.51 $100.19$0.00$0.20 $0.56 $0.750.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.75 $0.752A Tube Reservoir to Pump 1770-N0101-03-21Assemble sheathing and glueon end connections.S Not Applicable General Assembly Mech. Assembly, LC157 10.000$0.00 $35.51 $100.19$0.00$0.23 $0.64 $0.870.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.87 $0.873A Tube - Sol to Wastegate 1770-N0101-03-41Assemble sheathing S Not Applicable General Assembly Mech. Assembly, LC300 10.000$0.00 $35.51 $100.19$0.00$0.12 $0.33 $0.450.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.45 $0.45Purchase Part - High Impact Item (Full Cost Mapping)1A Tube Reservoir to Solenoid 1770-N0101-03-1-11Extrude and Form S Nylon12, Inject. Extruding/DrawingOperator Comp./Ext. Mold, LMC400 1.50.009$3.03 $54.35 $100.04 $0.03 $0.20 $0.25 $0.480.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.48 $0.482A Tube Preformed 1770-N0101-03-2-11Extrude and Form S Nylon12, Inject. Extruding/DrawingOperator Comp./Ext. Mold, LMC257 1.50.020$3.03 $54.35 $100.04 $0.06 $0.32 $0.39 $0.770.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.77 $0.773A Tube - Sol to Wastegate 1770-N0101-03-4-11Extrude S Thermoset-SBR Extruding/Drawing Operator Comp./Ext. Mold, LMC514 0.50.095$1.32 $54.35 $100.04 $0.13 $0.05 $0.19 $0.370.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.37 $0.37Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Hose Tube end connections 1770-N0101-03-1-24Rubber S$0.00$0.04$0.00 $0.162A Sheath Tube-Short 1770-N0101-03-1-31Nylon S$0.00$0.20$0.00 $0.203A Sheath Tube - medium 1770-N0101-03-2-21Nylon S$0.00$0.50$0.00 $0.504A Sheath Tube-Long 1770-N0101-03-4-21Nylon S$0.00$0.60$0.00 $0.605A Zip Tie - tube to tube 1770-N0101-03-33S$0.00$0.02$0.00 $0.066A Zip Tie Edge Bitter - tube to tube 1770-N0101-03-61S$0.00$0.12$0.00 $0.127A Isolator/Hose wrap 1770-N0101-03-51S$0.00$0.08$0.00 $0.08Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$5.41T1 or OEM Total Manufacturing Cost:$1.93 $1.12 $2.36 $5.41 $0.00 $0.00 $0.00 $0.00 $0.00 $5.41T1 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 $0.61Base Cost Impact to Vehicle:$1.93 $1.12 $2.36 $5.41 $0.02 $0.32 $0.22 $0.05 $0.61 $6.03 $0 $0Packaging Cost:$0.10Net Cost Impact to Vehicle:$6.12Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.013 $26,5960.00%2,250,000 605.00%$200133432657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.09$1.00 10 $3.00 9 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.099109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTPackaging Option #1 with expendabledividers.12 Cells per Layer, 4 parts per Cell.9 Layers.Total # of Parts/Pallet =432"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-15, 6 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Assembly-Inlet 1570BManufacturing Assumption and Quote SummaryAPPENDIX G.1-15 (4of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Tube Ass'y w. Vehicle Tie Down Canister, Air CoolerInletPart Number:1570-N0101-20/21/22Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Resonator Tube Sub-Assembly 1570-N0101-211Spin Weld Housing Inner toBaffle InnerS Not Applicable General Assembly Mech. Assembly, LC300 30.000$0.00 $35.51 $100.19$0.00$0.36 $0.33 $0.690.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.69 $0.692ATube Ass'y w. Vehicle Tie Down Canister, AirCooler1570-N0101-191Assembly Tubes to Resonator S Not Applicable General Assembly Mech. Assembly, LC200 30.000$0.00 $35.51 $100.19$0.00$0.53 $0.50 $1.030.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.03 $1.03Purchase Part - High Impact Item (Full Cost Mapping)1A Hose Long 1570-N0101-19-21Extrude and Form SSBR-Fiber Rein.,ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC295 1.50.691$1.85 $54.35 $100.04 $1.28 $0.28 $0.34 $1.890.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.89 $1.891B Hose Long w. Overmold Clamp 1570-N0101-19-21Overmold Clamp to Hose S Not Applicable Extruding/Drawing Operator Comp./Ext. Mold, LMC240 10.000$0.00 $54.35 $100.04$0.00$0.23 $0.42 $0.640.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.64 $0.642A Hose Short Preformed 1570-N0101-19-61Extrude and Form SSBR-Fiber Rein.,ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC450 1.50.387$1.85 $54.35 $100.04 $0.71 $0.18 $0.22 $1.120.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.12 $1.123A Housing Outer Shell 1570-N0101-19-4-11Injection Mold S Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS554 0.250.513$1.54 $43.52 $100.01 $0.79 $0.02 $0.18 $0.990.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.99 $0.993B Baffle Inner Tube & End Cap 1570-N0101-19-4-21Injection Mold S Nylon66-50GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS610 0.250.203$1.54 $43.52 $100.01 $0.31 $0.02 $0.16 $0.490.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.49 $0.49Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Hose Clamp 1570-N0101-19-332" S$0.00$0.27$0.00 $0.812A Sleeve Tube Anti-Crush 1570-N0101-19-4-32Steel, Nickel/Zinc Plate S$0.00$0.30$0.00 $0.603A Hose clamp 1570-N0101-19-812" w. Retention Teeth S$0.00$0.35$0.00 $0.354A Grommet Fastener Isolator 1570-N0101-19-4-41S$0.00$0.08$0.00 $0.085A Sleeve Anti-Crush, Fastener 1570-N0101-19-4-51S$0.00$0.05$0.00 $0.05Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$8.75T1 or OEM Total Manufacturing Cost:$4.98 $1.61 $2.16 $8.75 $0.00 $0.00 $0.00 $0.00 $0.00 $8.75T1 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 $0.99Base Cost Impact to Vehicle:$4.98 $1.61 $2.16 $8.75 $0.03 $0.53 $0.35 $0.09 $0.99 $9.74 $0 $0Packaging Cost:$0.08Net Cost Impact to Vehicle:$9.82Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.030 $59,8400.00%2,250,000 605.00%$200299192657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.05$1.00 9 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.077109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTOption #1 with Tier Pad DividersPart Size =600x180x110Parts per Pallet = 2 Rows of 12, 8layers= 192 parts"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-15, 7 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Assembly-Outlet-1570CManufacturing Assumption and Quote SummaryAPPENDIX G.1-15(5of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Tube Ass'y w. Vehicle Tie Down Canister, Air CoolerOutletPart Number:1570-N0101-30Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Tube 1570-N0101-30-51Install Inserts and Grommets S Not Applicable GeneralAssembly Mech. Assembly, LC240 50.000$0.00 $35.51 $100.19$0.00$0.74 $0.42 $1.160.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.16 $1.162 Tube - Charge Air Cooler Outlet 1570-N0101-301Install Hose, Clamp S Not Applicable General Assembly Mech. Assembly, LC180 20.000$0.00 $35.51 $100.19$0.00$0.39 $0.56 $0.950.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.95 $0.95Purchase Part - High Impact Item (Full Cost Mapping)1A Tube 1570-N0101-30-51Friction Weld S Not Applicable Mold/Cast/Sinter Operator Inject. Mold, SMS180 30.000$0.00 $43.52 $100.01$0.00$0.73 $0.56 $1.280.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.28 $1.281B Tube 1570-N0101-30-5-21Extrude & Blow Form Tube S Nylon6-15GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS145 11.612$1.59 $43.52 $100.01 $2.56 $0.30 $0.69 $3.550.00% 0.00% 0.00% 0.00%0.00% $0.00 $3.55 $3.552A Tube Attachment #1 1570-N0101-30-5-311Injection Mold S Nylon6-15GF, Inject. Mold/Cast/SinterOperator Inject. Mold, SMS720 0.250.015$1.59 $43.52 $100.01 $0.02 $0.02 $0.14 $0.180.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.18 $0.183A Tube Attachment #2 1570-N0101-30-5-321Injection Mold S Nylon6-15GF, Inject. Mold/Cast/SinterOperator Inject. Mold, SMS720 0.250.015$1.59 $43.52 $100.01 $0.02 $0.02 $0.14 $0.180.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.18 $0.184A Tube Attachment #3 1570-N0101-30-5-331Injection Mold S Nylon6-15GF, Inject. Mold/Cast/SinterOperator Inject. Mold, SMS720 0.250.015$1.59 $43.52 $100.01 $0.02 $0.02 $0.14 $0.180.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.18 $0.185A Hose preformed 1570-N0101-30-31Extrude and Form SSBR-Fiber Rein., ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC367 1.50.676$1.85 $54.35 $100.04 $1.25 $0.22 $0.27 $1.740.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.74 $1.745B Hose w/Clamps 1570-N0101-30-11Overmold Clamp to Hose S Not Applicable Extruding/Drawing Operator Comp./Ext. Mold, LMC240 10.000$0.00 $54.35 $100.04$0.00$0.23 $0.42 $0.640.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.64 $0.64Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Insert Brass Threaded 1570-N0101-30-61S$0.00$0.04$0.00 $0.042A Sleeve Tube Anti-Crush 1570-N0101-19-4-32S$0.00$0.30$0.00 $0.603A Grommet Fastener Isolator 1570-N0101-19-4-41S$0.00$0.08$0.00 $0.084A Sleeve Anti-Crush, Fastener 1570-N0101-19-4-51S$0.00$0.05$0.00 $0.055A Nut - Flag w/Isolator 1570-N0101-30-71S$0.00$0.25$0.00 $0.256A Sleeve Anti Crush 1570-N0101-30-81S$0.00$0.30$0.00 $0.307A Hose Clamp 1570-N0101-30-42S$0.00$0.29$0.00 $0.588ASensor - Intake Temperature, Outlet Charged Air Co1599-N0101-031S$0.00$5.00$0.00 $5.009A Bolt - Sensor, Charge Air Temperature 1580-N0101-101S$0.00$0.04$0.00 $0.04Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$16.81T1 or OEM Total Manufacturing Cost:$10.83 $2.65 $3.32 $16.81 $0.00 $0.00 $0.00 $0.00 $0.00 $16.81T1 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 $1.90Base Cost Impact to Vehicle:$10.83 $2.65 $3.32 $16.81 $0.05 $1.01 $0.67 $0.17 $1.90 $18.70 $0 $0Packaging Cost:$0.06Net Cost Impact to Vehicle:$18.76Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.057 $227,3940.00%4,500,000 605.00%$38059896657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.057109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTPallet Option #2,Part Size = 600x150x140Parts per Pallet = 2 Rows, 8 per row, 6Layers = 96 Parts per Pallet"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-15, 8 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Assembly-Outlet-1570DManufacturing Assumption and Quote SummaryAPPENDIX G.1-15(6of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Tube - Elbow, Upper to Charged Air Coupler By-PassPart Number:1570-N0101-40Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Tube - Elbow, Upper to Charged Air Coupler ByPas1570-N0101-401Crimp End Hose Piece ontoHose and Add O-RingS Not Applicable General Assembly Mech. Assembly, LC240 10.000$0.00 $35.51 $100.19$0.00$0.15 $0.42 $0.570.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.57 $0.57Purchase Part - High Impact Item (Full Cost Mapping)1A Tube (Hose) preformed 1570-N0101-40-11Extrude and Form SSBR-Fiber Rein.,ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC400 1.50.620$1.85 $54.35 $100.04 $1.15 $0.20 $0.25 $1.600.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.60 $1.601B Tube (Hose) w/Clamps 1570-N0101-40-1-11Overmold Clamp to Hose S Not Applicable Extruding/Drawing Operator Comp./Ext. Mold, LMC240 10.000$0.00 $54.35 $100.04$0.00$0.23 $0.42 $0.640.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.64 $0.64Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End ItemHose Clamp 1570-N0101-40-21S$0.00$0.25$0.00 $0.25Hose end piece 1570-N0101-40-31S$0.00$0.75$0.00 $0.75O-ring Seal Tube OD 1570-N0101-40-41S$0.00$0.11$0.00 $0.110$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$3.92T1 or OEM Total Manufacturing Cost:$2.26 $0.58 $1.08 $3.92 $0.00 $0.00 $0.00 $0.00 $0.00 $3.92T1 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 $0.44Base Cost Impact to Vehicle:$2.26 $0.58 $1.08 $3.92 $0.01 $0.24 $0.16 $0.04 $0.44 $4.36 $0 $0Packaging Cost:$0.03Net Cost Impact to Vehicle:$4.39Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.010 $19,9470.00%2,250,000 605.00%$200100576657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.02$1.00 10 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.027109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTPackage Option #1Part Size = 200x140x90mmEach Layer = 4 rows of 16Number of Layers = 9Total Parts per Pallet = 576"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-15, 9 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Inlet ETB-1570Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15 (7of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Part Number:1570-N0101-41/42/43/44Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Flex Tube Silencer to Environment1070-N0101-05-3(1570-N0101-44)1Heat Stake Cap to Flex Tubeand add foam.S Not Applicable General Assembly Mech. Assembly, LC240 10.000$0.00 $35.51 $100.19$0.00$0.15 $0.42 $0.570.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.57 $0.572A Silencer - Charge Air By-Pass1070-N0101-05-2(1599-N0101-04)1Insert Inner Baffle andVibration Weld HousingS Not Applicable General Assembly Mech. Assembly, LC240 10.000$0.00 $35.51 $100.19$0.00$0.15 $0.42 $0.570.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.57 $0.573AHose Ass'y Silencer to Y Couple(Tube - Charged Air Bypass to Silencer)1070-N0101-05-5(1570-N0101-43)1Assemble Protective Sheathand IsolatorS Not Applicable General Assembly Mech. Assembly, LC300 10.000$0.00 $35.51 $100.19$0.00$0.12 $0.33 $0.450.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.45 $0.454A Tube Inlet to throttle body1070-N0101-05(1570-N0101-42)1Assemble Individual TubeAssemblies with clampsS Not Applicable General Assembly Mech. Assembly, LC120 40.000$0.00 $35.51 $100.19$0.00$1.18 $0.83 $2.020.00% 0.00% 0.00% 0.00%0.00% $0.00 $2.02 $2.02Purchase Part - High Impact Item (Full Cost Mapping)1A Tube - Flex Elbow, Silencer to Environment1070-N0101-05-15-1(1570-N0101-44)1Injection Mold S TPE-PP/EPDM, Inject. Mold/Cast/SinterOperator Inject. Mold, SMS710 10.205$0.99 $43.52 $100.01 $0.20 $0.06 $0.14 $0.410.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.41 $0.412ATube - Flex Elbow, Silencer to Environment,Snap1070-N0101-05-15-2(1570-N0101-44)1Injection Mold S Nylon6-15GF, Inject. Mold/Cast/SinterOperator Inject. Mold, SMS720 0.50.020$1.59 $43.52 $100.01 $0.03 $0.03 $0.14 $0.200.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.20 $0.203A Silencer Outer Shell 1070-N0101-05-2-11Injection Mold S PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS509 0.50.270$1.45 $43.52 $100.01 $0.39 $0.04 $0.20 $0.630.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.63 $0.634A Silencer Inner Baffle 1070-N0101-05-2-1-2-31Injection Mold S PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS986 0.50.140$1.45 $43.52 $100.01 $0.20 $0.02 $0.10 $0.330.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.33 $0.335A Silencer End Cap 1070-N0101-05-2-1-21Injection Mold S PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS900 0.50.140$1.45 $43.52 $100.01 $0.20 $0.02 $0.11 $0.340.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.34 $0.346A Tube (Hose) preformed 1570-N0101-40-11Extrude and Form SSBR-Fiber Rein., ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC383 1.50.380$1.85 $54.35 $100.04 $0.70 $0.21 $0.26 $1.180.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.18 $1.187A Tube Y-Coupler to bypass1070-N0101-05-8-1(1570-N0101-41)1Injection Mold S Nylon6-30GF, Inject. Mold/Cast/SinterOperator Inject. Mold, SMS923 0.50.289$1.76 $43.52 $100.01 $0.51 $0.02 $0.11 $0.640.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.64 $0.648AElbow Coupler Bypass to Throttle(Tube-Elbow Coupler By-Pass to Throttle Body)1070-N0101-05-10-1(1570-N0101-42)1Extrude and Form SSBR-Fiber Rein., ExtrudedExtruding/Drawing Operator Comp./Ext. Mold, LMC343 1.50.723$1.85 $54.35 $100.04 $1.34 $0.24 $0.29 $1.870.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.87 $1.878BElbow Coupler Bypass to Throttle w. Clamp(Tube-Elbow Coupler By-Pass to Throttle Body)1070-N0101-05-11(1570-N0101-42)1Overmold Clamp to Hose S Not Applicable Extruding/Drawing Operator Comp./Ext. Mold, LMC240 10.000$0.00 $54.35 $100.04$0.00$0.23 $0.42 $0.640.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.64 $0.64Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchase PriceNet, PIAPurchase PriceNet, End Item1A Seal foam press in place tape style 1070-N0101-05-161S$0.00$0.10$0.00 $0.102A Grommet - Silencer to Engine 1070-N0101-05-991S$0.00$0.15$0.00 $0.153A Sheath Hose Protection 1070-N0101-05-141S$0.00$0.38$0.00 $0.384A Isolator Hose 1070-N0101-05-71S$0.00$0.12$0.00 $0.125A Hose Clamp lrg end molded in place 1070-N0101-05-121S$0.00$0.40$0.00 $0.406a Hose Clamp sml end 1070-N0101-05-111S$0.00$0.27$0.00 $0.277a Hose Clamp 1070-N0101-05-43S$0.00$0.16$0.00 $0.480$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotal Mark-up$11.73T1 or OEM Total Manufacturing Cost:$5.48 $2.48 $3.77 $11.73 $0.00 $0.00 $0.00 $0.00 $0.00 $11.73T1 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 $1.33Base Cost Impact to Vehicle:$5.48 $2.48 $3.77 $11.73 $0.04 $0.70 $0.47 $0.12 $1.33 $13.05 $0 $0Packaging Cost:$0.07Net Cost Impact to Vehicle:$13.1247450,0001450,000North AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsMARK-UP COSTSGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTube: 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 EnvironmentTOTAL COSTSTOOLING & INVESTMENT109,574"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-15, 10 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Tube Inlet ETB-1570Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15 (7of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Part Number:1570-N0101-41/42/43/44Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "47450,0001450,000North AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsMARK-UP COSTSGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTube: 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 EnvironmentTOTAL COSTSTOOLING & INVESTMENT109,574Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customer andIn-transitInventoryRequirements(Weeks)Supplier,Customer and Intransit InventoryRequirements(Parts)Rack/Pallet Investment Amortization:$0.066 $131,6490.00%2,250,000 605.00%$22059896657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3 PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.066Pallet Options: Option #1 No Tier Pads, 8Cell Returnable Pallet DividersPart Size: 600x300x100Parts/Layer = 2x4 = 8Number of Layers = 12File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-15, 11 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Bracket-Support Turbo 1575Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15(8of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Bracket - Support, Turbo AssemblyPart Number:1575-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Bracket - Support, Turbo Assembly1575-N0101-01(1275-N0101-04)1Forging S S-Steel-304, Bar Forging Operator Cold Forge,LMC257 10.649$1.65 $38.52 $100.09 $1.07 $0.15 $0.39 $1.610.00% 0.00% 0.00% 0.00%0.00% $0.00 $1.61 $1.61Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item0$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$1.61T1 or OEM Total Manufacturing Cost:$1.07 $0.15 $0.39 $1.61 $0.00 $0.00 $0.00 $0.00 $0.00 $1.61T1 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 $0.17Base Cost Impact to Vehicle:$1.07 $0.15 $0.39 $1.61 $0.00 $0.10 $0.06 $0.00 $0.17 $1.78 $0 $0Packaging Cost:$0.06Net Cost Impact to Vehicle:$1.84Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.001 $1,5960.00%2,250,000 605.00%$100163600657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.06$0.00 0 $0.00 0 $3.50 60 $0.00 0 $0.00 0Packaging Cost Total:$0.059109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTPackaged in Expendible Card BoardBoxes(Weight Consideration<40lbs)Card Board Box: 300x220x120($3.50/Box)Parts per Box: 15 per layer x 4Layers/Box = 60 Parts/BoxPer Pallet (1/2 Pallet), 4x5 Boxes perlayer3 layers = 60 Boxes"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-15, 12 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Vac. Reservoir 1599Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15(9of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Vacuum Reservoir - Turbo Waste GatePart Number:1599-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Vacuum Reservoir7070-N0101-02(1599-N01010-01)1Vibration Weld and AssemblyInsertsS Not Applicable General Assembly Mech. Assembly, LC240 20.000$0.00 $35.51 $100.19$0.00$0.30 $0.42 $0.710.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.71 $0.71Purchase Part - High Impact Item (Full Cost Mapping)1A Cover - cap: Vacuum Reservoir 7070-N0101-02-11PA6 GF35 S Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS1037 0.50.158$1.76 $43.52 $100.01 $0.28 $0.02 $0.10 $0.400.30% 6.00% 4.00% 0.00%10.30% $0.04 $0.44 $0.442A Base Reservoir: Vacuum Reservoir 7070-N0101-02-21PA6 GF35 S Nylon6-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS861 0.50.454$1.76 $43.52 $100.01 $0.80 $0.03 $0.12 $0.940.30% 6.00% 4.00% 0.00%10.30% $0.10 $1.04 $1.04Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Anti-Crush Sleeves Vacuum Reservoir 7070-N0101-02-33$0.00$0.04$0.12 $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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$2.19T1 or OEM Total Manufacturing Cost:$1.08 $0.34 $0.63 $2.05 $0.00 $0.08 $0.05 $0.00 $0.14 $2.19T1 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 $0.34Base Cost Impact to Vehicle:$1.08 $0.34 $0.63 $2.05 $0.01 $0.22 $0.18 $0.05 $0.48 $2.53 $0 $0Packaging Cost:$0.10Net Cost Impact to Vehicle:$2.63Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.017 $33,4970.00%2,250,000 605.00%$200167343657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.08$1.00 8 $3.00 7 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.101109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTPallet Option #1 w. Disposable TierPadsPart Size:170x150x115Parts Layer = 7x7 =49Number of Layers = 7"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-15, 13 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Valve-Thrust Control 1599Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15 (10of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Value - Thrust Control, Turbo Waste Gate PneumaticControlPart Number:1599-N0101-02Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1AValue - Thrust Control, Turbo Waste GatePneumatic Control1599-N0101-021(Look @ Evaluating as LowImpact Supplier)S$0.00$5.19$0.00 $5.190$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$5.19T1 or OEM Total Manufacturing Cost:$5.19 $0.00 $0.00 $5.19 $0.00 $0.00 $0.00 $0.00 $0.00 $5.19T1 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 $0.80Base Cost Impact to Vehicle:$5.19 $0.00 $0.00 $5.19 $0.03 $0.34 $0.31 $0.13 $0.80 $5.99 $0 $0Packaging Cost:$0.02Net Cost Impact to Vehicle:$6.02Packaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.024 $48,9800.00%2,250,000 605.00%$4,420115184657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.024109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTPackaging Option #3 w. ReturnableTraysPart Size 80x90x50Parts/Layer = 6x3 = 18Number of Layers = 6"S"=Indicates Component is Supplied directly to T1or OEM forFinal or Sub-Assembly."SAC"=(Supplier Accounted Costs) Indicates Component isSupplied directly to T1 or OEM for Final or Sub-Assembly. Inaddition component material cost is accounted for in T1 quotesheet. Thus component cost will only be included for Mark-upCalculations."Alpha-Numeric Character" = Indicates purchase parts arebrought in by T2/T3 Supplier for Subassembly.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-15, 14 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 1500Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15 (11of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:OEM Vehicle AssemblySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Engine And Vehicle AssemblyPart Number:1500-N0101-01Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Turbo Charging Assembly 1501-N0101-011Mount Turbo Assembly toIntake Manifold, 4 NutsOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM82 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$1.02 $1.53 $2.55 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.55 $2.552A Bracket - Support, Turbo Assembly 1575-N0101-011Install Turbo Support Bracket, 2BoltsOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM97 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$0.86 $1.29 $2.14 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.14 $2.143A Vacuum Reservoir - Turbo Waste Gate 1599-N0101-011Install Vacuum Reservoir, 2Bolts and 1 NutOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM90 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$0.93 $1.39 $2.32 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.32 $2.324AValue - Thrust Control, Turbo Waste GatePneumatic Control1599-N0101-021Install Valve to Mount Bracket,No Additional FastenerOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM240 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$0.35 $0.52 $0.87 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.87 $0.875ATube Assembly - Turbo Waste Gate PneumaticControl1570-N0101-031Install Waste Gate Tubing, 6Attachment PointsOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM73 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$1.13 $1.70 $2.84 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.84 $2.846A Cooler Assembly - Charged Air 1505-N0101-011Install Vehicle H/W for ChargedAir Cooler and Charged AirCooler.OEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM49 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$1.71 $2.57 $4.29 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $4.29 $4.297ATube Ass'y w. Vehicle Tie Down Canister, AirCooler Inlet1570-N0101-20/21/221Install Tube Assembly, TurboAssembly to Charged AirCoolerOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM75 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$1.11 $1.67 $2.78 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.78 $2.788ATube Ass'y w. Vehicle Tie Down Canister, AirCooler Outlet1570-N0101-301Install Tube Assembly,Charged Air Cooler toCoupler/ETB bypassOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM61 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$1.37 $2.05 $3.42 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $3.42 $3.429ATube - Elbow, Upper to Charged Air Coupler By-Pass1570-N0101-401Make Connection BetweenCharged Air Outlet Tube andElectronic Throttle Body InletTube.OEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM189 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$0.44 $0.66 $1.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.10 $1.1010ATube: Coupler Y Branch to By-Pass/ElbowCoupler By-Pass to Throttle Body/ElbowCoupler By-Pass to Throttle Body/Tube - FlexElbow, Silencer to Environment1570-N0101-41/42/43/441Make Connection to ThrottleBody and Snap in Bypass Tubeto Vehicle BodyOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Vehicle Operations, OEM92 1 1 10.000$0.00 $83.31 $125.21 $125.21$0.00$0.90 $1.36 $2.26 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.26 $2.26Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Turbo Charging Assembly 1501-N0101-011SAC$151.85$151.85$0.00 $151.852A Bracket - Support, Turbo Assembly 1575-N0101-011SAC$1.84$1.84$0.00 $1.843A Vacuum Reservoir - Turbo Waste Gate 1599-N0101-011SAC$2.63$2.63$0.00 $2.634AValue - Thrust Control, Turbo Waste GatePneumatic Control1599-N0101-021SAC$6.02$6.02$0.00 $6.025ATube Assembly - Turbo Waste Gate Pneumatic Control1570-N0101-031SAC$6.12$6.12$0.00 $6.126A Cooler Assembly - Charged Air 1505-N0101-011SAC$18.65$18.65$0.00 $18.657ATube Ass'y w. Vehicle Tie Down Canister, AirCooler Inlet1570-N0101-20/21/221SAC$9.82$9.82$0.00 $9.828ATube Ass'y w. Vehicle Tie Down Canister, AirCooler Outlet1570-N0101-301SAC$18.76$18.76$0.00 $18.769ATube - Elbow, Upper to Charged Air Coupler By-Pass1570-N0101-401SAC$4.39$4.39$0.00 $4.3910ATube: Coupler Y Branch to By-Pass/ElbowCoupler By-Pass to Throttle Body/ElbowCoupler By-Pass to Throttle Body/Tube - FlexElbow, Silencer to Environment1570-N0101-41/42/43/441SAC$0.00$0.00$0.00 $0.0011A Nut - Exhaust Manifold to Turbo 1280-N0101-074S$0.00$0.14$0.00 $0.5712A Bolt - Bracket Support, Turbo Assembly 1580-N0101-031S$0.00$0.05$0.00 $0.0513A Bolt - Bracket Support, Turbo Assembly 1580-N0101-041S$0.00$0.04$0.00 $0.0414A Bolt - Pressure Reservoir, Turbo Waste Gate 1580-N0101-052S$0.00$0.05$0.00 $0.0915A Nut - Pressure Reservoir, Turbo Waste Gate 1580-N0101-061S$0.00$0.01$0.00 $0.0116A Bolt - Tube, Charge Air Cooler to Vehicle 1580-N0101-092Hardware Not Available S$0.00$0.04$0.00 $0.0717A Internal Threaded Part ( Vehicle H/W) NA2Hardware Not Available S$0.00$0.03$0.00 $0.0518A Isolators Veh. Mnt. Charged Air Cooler NA2S$0.00$0.08$0.00 $0.1619ABolt - Tube Ass'y w. Vehicle Canister Tie Down....NA1Hardware Not Available S$0.00$0.01$0.00 $0.019,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENT"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.Full QuoteModification QuoteDifferential Quote (Quote Summary includes costingforboth Technology Packages)File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3APpendix G.1-15, 15 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 1500Manufacturing Assumption and Quote SummaryAPPENDIX G.1-15 (11of11)Print Date:9/1/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:OEM Vehicle AssemblySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Engine And Vehicle AssemblyPart Number:1500-N0101-01Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTFull QuoteModification QuoteDifferential Quote (Quote Summary includes costingforboth Technology Packages)20AInternal Threaded Part ( Vehicle H/W Inlet (1 pc)& Outlet (2 pcs) Air Tube Canister Tie Down)NA3Hardware Not Available S$0.00$0.02$0.00 $0.0521A Bolt - Tube Charged Air Cooler Outlet NA2Hardware Not Available S$0.00$0.01$0.00 $0.0222A Screw Tube Intake Manifold to Attachment NA1Hardware Not Available S$0.00$0.01$0.00 $0.01Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$245.77T1 or OEM Total Manufacturing Cost:$221.21 $9.81 $14.75 $245.77 $0.00 $0.00 $0.00 $0.00 $0.00 $245.77T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:(220.07)----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$1.14 $9.81 $14.75 $25.70 $0.00 $0.00 $0.00 $0.00 $0.00 $25.70 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$25.70Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000PACKAGING CALCULATIONS:No Packaging Considerations Required. PackagingCosts for fasteners (bolts, nuts, etc.) is capturedin thepiece costs.31File:15 Air Induction Charging System 040109A.xlsEPA Contract: EP-C-07-069 WA1-3APpendix G.1-15, 16 of 16Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 17Breather SubsystemCase Study #0101MAQS WorksheetsFile:Breather Subsystem 17 040209.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-17, 1 of 2Oil-Air Separator 1702Manufacturing Assumption and Quote SummaryAPPENDIX G.1-17 (1of1)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Oil/Air SeparatorPart Number:1702-N0101-00Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Oil/Air Separator 1702-N0101-001Final Assembly of PCV systemto cover.T1 Assembly, Mark-up Applied@ Bottom.Not Applicable General Assembly Mech Assembly, LC, Base257 1 1 30.000$0.00 $35.51 $15.00 $45.00$0.00$0.14 $0.18 $0.31 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.31 $0.310##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - High Impact Item (Full Cost Mapping)1AValve - Non Return Intake Hose & Manifold Side1702-N0101-01/41-012Injection Mold Flap withovermold HingeT2/T3 Inject. Mold, MSMC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS720 1 1 10.005$1.54 $43.52 $100.01 $100.01 $0.01 $0.06 $0.14 $0.21 0.50% 6.50% 6.00% 1.00% 14.00% $0.03 $0.24 $0.471BValve - Non Return Intake Hose & Manifold Side1702-N0101-01/41-022Two Shot Overmold T2/T3 Inject. Mold, MSMC Thermoset-NBR Mold/Cast/Sinter Operator Inject. Mold, SMS800 0 1 10.002$1.27 $43.52 $100.01 $100.01 $0.00$0.00$0.13 $0.13 0.50% 6.50% 6.00% 1.00% 14.00% $0.02 $0.15 $0.292A Separator - Cyclone 1702-N0101-101Injection Mold (AdditionalPlastic added to Mini Coverover GEMA cover)T2/T3 Inject. Mold, MSMC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, MLS545 0 1 10.818$1.54 $43.52 $150.01 $150.01 $1.26$0.00$0.28 $1.53 0.50% 6.50% 6.00% 1.00% 14.00% $0.21 $1.75 $1.753AValve - Pressure Control1702-N0101-201Nylon Injection Mold T2/T3 Inject. Mold, MSMC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS391 1 1 10.005$1.54 $43.52 $100.01 $100.01 $0.01 $0.11 $0.26 $0.37 0.50% 6.50% 6.00% 1.00% 14.00% $0.05 $0.43 $0.433BValve - Pressure Control1702-N0101-201Two Shot Overmold T2/T3 Inject. Mold, MSMC Thermoset-NBR Mold/Cast/Sinter Operator Inject. Mold, SMS389 0 1 10.002$1.27 $43.52 $100.01 $100.01 $0.00$0.00$0.26 $0.26 0.50% 6.50% 6.00% 1.00% 14.00% $0.04 $0.30 $0.300##### 0 1 10.000#N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Hinge Flow control flap 1702-N0101-802S$0.00$0.03$0.00 $0.060$0.00$0.00$0.00 $0.000$0.00$0.00$0.00 $0.000$0.00$0.00$0.00 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$3.61T1 or OEM Total Manufacturing Cost:$1.35 $0.37 $1.49 $3.21 $0.01 $0.18 $0.17 $0.03 $0.40 $3.61T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.02 $0.23 $0.22 $0.09 $0.56Base Cost Impact to Vehicle:$1.35 $0.37 $1.49 $3.21 $0.03 $0.42 $0.39 $0.12 $0.96 $4.17 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$4.17Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.0009,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTPACKAGING CALCULATIONS:No Packaging Impact"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:Breather Subsystem 17 040209.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-17, 2 of 2Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 60Engine Management, EngineElectronic, and ElectricalSubsystemsCase Study #0101MAQS WorksheetsFile:Electrical Subsystem 6000 040209.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-60, 1 of 5PCM HW 6002AManufacturing Assumption and Quote SummaryAPPENDIX G.1-60, (1of4)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Power Train Control Module (PCM) Assembly - HardwarePart Number:0602-N0101-01Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1APower Train Control Module (PCM) Assembly -Hardware0602-N0101-011The PCM H/W is carry overexcept for the PFI drivers. GDIdrivers use a 75-80VDC BoostCircuit and 25A Peak/HoldDrivers.The turbo is just another lowside driver really no cost.S$0.00$40.00$0.00 $40.000$0.00$0.00$0.00 $0.000$0.00$0.00$0.00 $0.000$0.00$0.00$0.00 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$40.00T1 or OEM Total Manufacturing Cost:$40.00 $0.00 $0.00 $40.00 $0.00 $0.00 $0.00 $0.00 $0.00 $40.00T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$40.00 $0.00 $0.00 $40.00 $0.00 $0.00 $0.00 $0.00 $0.00 $40.00 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$40.00Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:Packaging Type:NAPart Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includes costingfor both Technology Packages)File:Electrical Subsystem 6000 040209.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-60, 2 of 5Form Author: G. Kolwich(248)373-6000 Ext. 2411PCM SW 6002BManufacturing Assumption and Quote SummaryAPPENDIX G.1-60, (2of4)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 High Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Power Train Control Module (PCM) Assembly - SoftwarePart Number:6002-N0101-50Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1APower Train Control Module (PCM) Assembly -Software6002-N0101-501• Control system is much morecomplicated in order to controlinjection timing, split injections,fuel rail pressure, electric waterpump, electric thermostat, etc.S$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$0.00T1 or OEM Total Manufacturing Cost:$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$0.00Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.0009,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTPACKAGING CALCULATIONS:Packaging Type:NAPart Size:Parts/Layer:Number of Layers:"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includes costingfor both Technology Packages)Per discussion with BrianNelson, Software will be coveredby indirect cost multiplier.5/20/09File:Electrical Subsystem 6000 040209.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-60, 3 of 5Form Author: G. Kolwich(248)373-6000 Ext. 2411Electrical 6003Manufacturing Assumption and Quote SummaryAPPENDIX G.1-60 (3of4)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:T1 Moderate Assembly ComplexitySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)Part Number:6003-N0101-01/30Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Wire Turbo Connector 0603-N0101-302($0.50/Wire Circuit) S$0.00$0.50$0.00 $1.002A Wire Coolant Aux Pump 0603-N0101-303($0.50/Wire Circuit) S$0.00$0.50$0.00 $1.503A Clip Harness Retention2S$0.00$0.01$0.00 $0.024A Wire Waste Gate Sol 0603-N0101-302($0.50/Wire Circuit) S$0.00$0.50$0.00 $1.005A Wire Charge Air Temp 0603-N0101-304($0.50/Wire Circuit) S$0.00$0.50$0.00 $2.006A Clip Harness Retention1S$0.00$0.01$0.00 $0.017A Edge Biter Harness Retention3S$0.00$0.02$0.00 $0.068A Wire HP Fuel Pump Control2($0.50/Wire Circuit) S$0.00$0.50$0.00 $1.009A Wire Fuel Pressure Sensor 0603-N0101-303($0.50/Wire Circuit) S$0.00$0.50$0.00 $1.5010A Ignition Coil Assembly - Single Spark 0603-N0101-014S$0.00$1.01$0.00 $4.04$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$12.13T1 or OEM Total Manufacturing Cost:$12.13 $0.00 $0.00 $12.13 $0.00 $0.00 $0.00 $0.00 $0.00 $12.13T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$12.13 $0.00 $0.00 $12.13 $0.00 $0.00 $0.00 $0.00 $0.00 $12.13 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$12.13Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:Negligible Change to Packaging"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:Electrical Subsystem 6000 040209.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-60, 4 of 5Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine Assembly 6000Manufacturing Assumption and Quote SummaryAPPENDIX G.1-60 (4of4)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:OEM Engine AssemblySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)Part Number:6003-N0101-01-50Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Additional Electrical Connections due to Turbo &DI AddsNA1Install Connectors, SecureWiringOEM Engine Assembly Not Applicable General Assembly-OEM Engine Assembly, OEM52 1 1 10.000$0.00 $83.31 $150.21 $150.21$0.00$1.60 $2.88 $4.48 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $4.48 $4.48Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1APower Train Control Module (PCM) Assembly -Hardware0602-N0101-011SAC$40.00$40.00$0.00 $40.002APower Train Control Module (PCM) Assembly -Software6002-N0101-501SAC$0.00$0.00$0.00 $0.003AEngine Electrical Systems (including WiringHarnesses, Earth Straps, Ignition Harness,Coils, Sockets)0603-N0101-01/301SAC$12.13$12.13$0.00 $12.134A$0.00$0.00$0.00 $0.005A$0.00$0.00$0.00 $0.006A$0.00$0.00$0.00 $0.007A$0.00$0.00$0.00 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$56.61T1 or OEM Total Manufacturing Cost:$52.13 $1.60 $2.88 $56.61 $0.00 $0.00 $0.00 $0.00 $0.00 $56.61T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:(52.13)----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$0.00 $1.60 $2.88 $4.48 $0.00 $0.00 $0.00 $0.00 $0.00 $4.48 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$4.48Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.0009,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000GENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATESMARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTPACKAGING CALCULATIONS:Negligible Change to Packaging"S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModificationDifferential Quote (Quote Summary includesFile:Electrical Subsystem 6000 040209.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-60, 5 of 5Form Author: G. Kolwich(248)373-6000 Ext. 2411Appendix G.1 - Subsystem 70Accessory SubsystemCase Study #0101MAQS WorksheetsFile:70 Accessory System 040209.xlsEPA Contract:EP-C-07-069 WA1-3Appendix G.1-70, 1 of 4Vacuum PumpManufacturing Assumption and Quote SummaryAPPENDIX G.1-70, (1of2)\Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Vacuum Pump AssemblyPart Number:7004-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)1A Vacuum Pump Assembly 7004-N0101-011Final Assembly & TestVacuum PumpS Not Applicable General Assembly Mech. Assembly, MC240 30.000$0.00 $35.51 $125.19$0.00$0.44 $0.52 $0.970.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.97 $0.971B Base Vac Pump Rotor Support 7004-N0101-01-07-011Subassembly Exhaust and OilVent ValveS Not Applicable General Assembly Mech. Assembly, MC240 10.000$0.00 $35.51 $125.19$0.00$0.15 $0.52 $0.670.00% 0.00% 0.00% 0.00%0.00% $0.00 $0.67 $0.67Purchase Part - High Impact Item (Full Cost Mapping)1A Base Vac Pump rotor support Casting 7004-N0101-01-07-01-021Machine Casting S Not Applicable Mold/Cast/Sinter Operator Diecast, LMC257 10.000$0.00 $43.52 $100.05$0.00$0.17 $0.39 $0.560.30% 6.00% 4.00% 0.00%10.30% $0.06 $0.62 $0.621B Base Vac Pump rotor support Casting 7004-N0101-01-07-01-02-11Casting S Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC183 0.50.542$1.10 $43.52 $100.05 $0.60 $0.12 $0.55 $1.260.30% 6.00% 4.00% 0.00%10.30% $0.13 $1.39 $1.392A Plate Oil vent relief 7004-N0101-01-07-01-041Stamping & Heat Treat S SPR-Steel, Coil Cut/Punch/Forming OperatorStamp/Form, SMS, LMC720 0.250.005$0.65 $42.18 $100.10 $0.00 $0.01 $0.14 $0.160.30% 6.00% 4.00% 0.00%10.30% $0.02 $0.17 $0.173A Plate retainer/limiter - Oil vent relief 7004-N0101-01-07-01-051Stamping & Plating S LC-Steel-1000S, Coil Cut/Punch/Forming OperatorStamp/Form, SMS, LMC720 0.250.008$0.45 $42.18 $100.10 $0.00 $0.01 $0.14 $0.160.30% 6.00% 4.00% 0.00%10.30% $0.02 $0.17 $0.174A Rotor Vac Pump 7004-N0101-01-081Induction Harden S Not Applicable Lathe/Turning Operator CNC Turning, MHC600 0.150.000$0.00 $37.60 $125.00$0.00$0.01 $0.21 $0.220.30% 6.00% 4.00% 0.00%10.30% $0.02 $0.24 $0.244B Rotor Vac Pump 7004-N0101-01-081Machine for Critical Tol. S Not Applicable Lathe/Turning Operator CNC Turning, MHC109 0.850.000$0.00 $37.60 $125.00$0.00$0.29 $1.15 $1.440.30% 6.00% 4.00% 0.00%10.30% $0.15 $1.59 $1.594C Rotor Vac Pump raw part 7004-N0101-01-08-1-11PM Sinter S PM-SMF-FN0205 Mold/Cast/Sinter Operator Powder Metal, MHC240 0.50.631$2.00 $43.52 $150.14 $1.26 $0.09 $0.63 $1.980.30% 6.00% 4.00% 0.00%10.30% $0.20 $2.18 $2.185A Adapter Rotor Drive 7004-N0101-01-091PM Sinter S PM-SMF-FC0208 Mold/Cast/Sinter Operator Powder Metal, LMC360 0.50.139$1.00 $43.52 $100.14 $0.14 $0.06 $0.28 $0.480.30% 6.00% 4.00% 0.00%10.30% $0.05 $0.53 $0.536A Retainer Rotor drive adapter 7004-N0101-01-101Stamp & Plate S LC-Steel-1000S, Coil Cut/Punch/FormingOperatorStamp/Form, SMS, LMC1200 0.250.001$0.45 $42.18 $100.10 $0.00 $0.01 $0.08 $0.090.30% 6.00% 4.00% 0.00%10.30% $0.01 $0.10 $0.107A Vane Vacuum Pump 7004-N0101-01-051Form Edges and Plate S Not Applicable Cut/Punch/Forming OperatorStamp/Form, SMS, LMC720 0.250.000$0.00 $42.18 $100.10$0.00$0.01 $0.14 $0.150.30% 6.00% 4.00% 0.00%10.30% $0.02 $0.17 $0.177B Vane Vacuum Pump 7004-N0101-01-05-011Stamp Out Form S LC-Steel-1000S, Coil Cut/Punch/Forming OperatorStamp/Form, SMS, LMC1200 0.250.167$0.45 $42.18 $100.10 $0.08 $0.01 $0.08 $0.170.30% 6.00% 4.00% 0.00%10.30% $0.02 $0.18 $0.188A Seal Pump Vane to wall 7004-N0101-01-062PM Sinter S Not Applicable Mold/Cast/Sinter Operator Powder Metal, LMC600 0.250.000$0.00 $43.52 $100.14$0.00$0.02 $0.17 $0.190.30% 6.00% 4.00% 0.00%10.30% $0.02 $0.20 $0.418B Seal Pump Vane to wall 7004-N0101-01-06-012PM Sinter S PM-SMF-FN0205 Mold/Cast/Sinter Operator Powder Metal, LMC480 0.250.026$2.00 $43.52 $100.14 $0.05 $0.02 $0.21 $0.280.30% 6.00% 4.00% 0.00%10.30% $0.03 $0.31 $0.639A Cover Vacuum Pump 7004-N0101-01-011Stamp & Plate S LC-Steel-1000S, Coil Cut/Punch/FormingOperatorStamp/Form, SMS, LMC180 11.070$0.45 $42.18 $100.10 $0.48 $0.23 $0.56 $1.270.30% 6.00% 4.00% 0.00%10.30% $0.13 $1.40 $1.4010A Fitting Vac Outlet Port 7004-N0101-01-031Assemble Outlet Fitting S Purchased Parts General Assembly Mech. Assembly, LC450 10.265$1.00 $35.51 $100.19 $0.27 $0.08 $0.22 $0.570.30% 6.00% 4.00% 0.00%10.30% $0.06 $0.62 $0.6210B Fitting Vac Outlet Port 7004-N0101-01-03-011Injection Mold Housing S Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS480 0.250.014$1.54 $43.52 $100.01 $0.02 $0.02 $0.21 $0.250.30% 6.00% 4.00% 0.00%10.30% $0.03 $0.28 $0.28Purchase Part - Commodity ( Value taken from Purchase Part Database)PurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End Item1A Fitting Clean Air Inlet 7004-N0101-01-07-01-031S$0.12$0.00 $0.122A Rivet solid, Oil vent plates 7004-N0101-01-07-01-061S$0.01$0.00 $0.013A Gasket Vac Pump Cover (SBR) 7004-N0101-01-021S$0.08$0.00 $0.084A Bolt - Vacuum Pump Housing 7080-N0101-104S$0.03$0.00 $0.125A Sleeve Anti Crush 7004-N0101-01-03-021B10A$0.01$0.01 $0.005B Check Valve 7004-N0101-01-03-031B10A$0.10$0.10 $0.005C Spring Check Valve 7004-N0101-01-03-041B10A$0.02$0.02 $0.005D Seat check valve spring 7004-N0101-01-03-051B10A$0.07$0.07 $0.005E O-Ring - Vac fitting 7004-N0101-01-041B10A$0.06$0.06 $0.006A Bolt - Vac Fitting 7080-N0101-101S$0.03$0.00 $0.03T1 or OEM Total Manufacturing Cost:$3.31 $1.81 $6.56 $11.69 $0.03 $0.58 $0.39 $0.00 $1.00 $12.68T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%T1 or OEM Mark-Up Values:----- ----- ----- -----$0.06 $0.82 $0.76 $0.32 $1.97Base Cost Impact to Vehicle:$3.31 $1.81 $6.56 $11.69 $0.09 $1.41 $1.15 $0.32 $2.96 $14.65 $0 $0Packaging Cost:$0.09Net Cost Impact to Vehicle:$14.74109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENT"S"=Indicates Component is Supplieddirectly to T1 or OEM for Final or SubAssembly."Alpha-Numeric Character" = Indicatespurchase parts are brought in by T2/T3Supplier for Subassembly.3File:70 Accessory System 040209.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-70, 2 of 4Form Author: G. Kolwich(248)373-6000 Ext. 2411Vacuum PumpManufacturing Assumption and Quote SummaryAPPENDIX G.1-70, (1of2)\Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual 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 TurboAnnual Component Volume: Packaging Specification:Component Description:Vacuum Pump AssemblyPart Number:7004-N0101-01Weekly Component Volume:Component Quote Level:Full QuoteXModification QuoteEstimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescription 

# OEM or SupplierMaterialSpecificationLabor ClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)MaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRateSG&ARateProfitRateED&T/R&DRateTotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "109,57447450,0001450,000MARK-UP COSTSNorth AmericaNorth AmericaF.O.BReturnable w.Expendable SeparatorsGENERAL COMPONENT INFORMATIONMANUFACTURING RATESGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSTOTAL COSTSTOOLING & INVESTMENTPackaging CalculationsCost perPieceTotalAmountLump SumPayment (%)Total # of PiecesNumber ofMonthsInterestRateCost perPallet /RackTotalNumber ofPallets/RacksRequiredNumber ofParts perPallet/ RackSupplier,Customerand IntransitInventoryRequirements (Weeks)Supplier,Customerand IntransitInventoryRequirements (Parts)Rack/Pallet Investment Amortization:$0.018 $35,4610.00%2,250,000 605.00%$200177432876596Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.08$1.00 9 $3.00 8 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.094Standard Pallet L4'xW4'xD3'Area = 122cm x 114 cm = 1440 sq. cmDepth = 86 cmPart Size 19x13x10Each Layer 9x6=54parts@ 8 layers = 432 PartsAssume Pallets Need to be ReplacedEvery 5 Years.File:70 Accessory System 040209.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-70, 3 of 4Form Author: G. Kolwich(248)373-6000 Ext. 2411Engine AssemblyManufacturing Assumption and Quote SummaryAPPENDIX G.1-70, (2of2)Print Date:9/2/2009Technology Level:Downsized, Turbocharged, Gasoline Direct Inject (GDI) Engine/ Compact Vehicle ClassOEM Operating Pattern (Weeks/Year): OEM Plant Location:Vehicle Class:Compact/Economy 2-4 PassengerAnnual Engine Volume (CPV): Supplier Plant Location:Study Case#:N0101 (N = New, 01 = Technology Package, 01 = Vehicle Class )Components per Engine: OEM/T1 Classification:OEM Engine AssemblySystem Description:2007 Mini Cooper S. 1.6L I4, 16V DOHC GDI TurboAnnual Component Volume: Shipping Method:Component Description:Engine Assembly of Accessory Subsystem Components to EnginePart Number:7000Weekly Component Volume: Packaging Specification:NAComponent Quote Level:Estimated Product Life:



# Reference #Part Description Part Number 

# QTY Per AssemblyPrimary ProcessDescriptionOEM/SupplierClassificationMaterialSpecificationLaborClassificationBurdenClassification 

# Finished Pieces Per Hour Number of Operators Number of Lines Parallel Processing

Multiplier Material Usage "lbs"MaterialCost$/lb(DB)LaborRate$/Hour(DB)BurdenRate$/Hour(DB)AppliedBurdenRate$/HourMaterialCostLabor/ PartBurden/Part 

# Total 1 =

Material + Labor + BurdenEndItemScrapRate(DB)SG&ARate(DB)ProfitRate(DB)ED&T/R&DRate(DB)TotalMark-upRateTotalMark-upCost 

# Total 2 =

Total 1 + Total Mark-up Total 3 =

Total 2 * Qty per Ass'y Tooling Assumptions

"x1000 " Investment Assumptions

"x1000 "Tier 1 Supplier or OEM Processing & Assembly (FullCost mapping)Vacuum Pump Assembly 7004-N0101-011Mount Vacuum Pump to HeadOEM Assembly, Mark-upApplied @ Bottom.Not Applicable General Assembly-OEM Engine Assembly,OEM113 1 1 10.000$0.00 $83.31 $150.21 $150.21$0.00$0.74 $1.34 $2.08 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.08 $2.08Purchase Part - Commodity ( Value taken from Purchase Part Database)SupplierAccountCostPurchasePrice/ UnitPurchasePrice Net,PIAPurchasePrice Net,End ItemBolt - Vacuum Pump 7080-N0101-012S$0.00$0.03$0.00 $0.05Seal - Vacuum Pump to Head 7004-N0101-01-111S$0.00$0.08$0.00 $0.080$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 $0.00Material Labor Burden TMC Scrap SG&A Profit ED&TTotalMark-up$2.20T1 or OEM Total Manufacturing Cost:$0.13 $0.74 $1.34 $2.20 $0.00 $0.00 $0.00 $0.00 $0.00 $2.20T1 or OEM Mark-Up Rates:----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%(SAC)&T1 or OEM Mark-Up Values:0.00----- ----- -----$0.00 $0.00 $0.00 $0.00 $0.00Base Cost Impact to Vehicle:$0.13 $0.74 $1.34 $2.20 $0.00 $0.00 $0.00 $0.00 $0.00 $2.20 $0 $0Packaging Cost:$0.00Net Cost Impact to Vehicle:$2.20Cost perPieceTotalAmountLump SumPayment(%)Total # ofPiecesNumber ofMonthsInterestRate 

# Cost per Pallet /Rack Total Number of Pallets/

Racks Required Number of Parts per Pallet/

RackSupplier, Customer and Intransit Inventory

Requirements (Weeks)Supplier, Customer and Intransit Inventory

Requirements (Parts)Rack/Pallet Investment Amortization:$0.000 $00.00%4,500,000 605.00%$0574471657447Cost perPieceTier PadPrice PerTier PadsPallet/RackDivider Pads,Price PerDivider PadsPallet/RackOther #1PackagingPrice PerOther #1PadsPallet/RackOther #2PackagingPrice PerOther #2PadsPallet/RackOther #3Packaging,Price PerOther #3PadsPallet/RackExpendable Packaging in Piece Cost:$0.00$0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0Packaging Cost Total:$0.000MARK-UP COSTSTOTAL COSTSTOOLING & INVESTMENTGENERAL COMPONENT INFORMATIONGENERAL MANUFACTURING INFORMATIONMANUFACTURING COSTSMANUFACTURING RATES9,57410North AmericaNorth AmericaFOB Ship Point47450,0001450,000PACKAGING CALCULATIONS:Packaging for fasteners covered in piece price."S"=Indicates Component is Supplied directly to T1or OEM for Final or SubAssembly."SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly toT1 or OEM for Final or Sub-Assembly. In addition component material cost isaccounted for in T1 quote sheet. Thus component cost will only be included forMark-up Calculations."Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3Supplier for Subassembly.31Full QuoteModification QuoteDifferential Quote (Quote Summary includesFile:70 Accessory System 040209.xlsEPA Contract: EP-C-07-069 WA1-3Appendix G.1-70, 4 of 4Form Author: G. Kolwich(248)373-6000 Ext. 2411