### Page:1 of 6 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/21/2012

DRAFT

Material Labor Burden End Item

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



# 140300 High Voltage Traction Battery **Subsy stem** 

1 **00 Assembly of High Voltage Traction Battery Subsystem**  **0.53 $**  **2.27**

**$ 0.60** 

**$ 3.40** 

**$**

**-**

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### 2 **01 Traction Battery**  **443.31 $**  **46.80**

**$ 181.11** 

**$ 671.22** 

**$ 4.85** 

**$ 49.11** 

**$ 55.56** 

**$ 27.19** 

**$ 136.71** 

**$ 2.33** 

**$ 810.26** 

**$**

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### 3 **03 Power Cabling > 12V Dc** 

**- $** 

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### 4 **70 Pipes, Hoses, Ducting** 

**- $** 

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### 5 **75 Brackets** 

**- $** 

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# BASE TECHNOLOGY GENERAL PART INFORMATION:

**System**

**ED&T/R&D**

**(x1000)** 

### Sub-Subsystem Description **Investment**

**(X1000)** Markup **Net**

**Component/**

**Assembly**

**Cost Impact to**

**OEM Total Markup** 

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly)**ItemSubsystem 

### Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)** 

# SYSTEM & SUBSYSTEM DESCRIPTION **NEW TECHNOLOGY GENERAL PART INFORMATION:**

**2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV**

**(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)**

Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly) Tooling** 

**(x1000)** 

# Technology **Level:** Mild Hybrid, Start

- Stop Technology

**Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers



# Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

6 **80 Boltings** 

**- $** 

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### 7 **85 Sealing Elements** 

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### 8 **90 Bearings Elements Misc** 

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### 9 **99 Miscellaneous** 

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### 09000064810e7549.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:2 of 6 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/21/2012

DRAFT

Material Labor Burden End Item

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

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**System**

**ED&T/R&D**

**(x1000)** 

### Sub-Subsystem Description **Investment**

**(X1000)** Markup **Net**

**Component/**

**Assembly**

**Cost Impact to**

**OEM Total Markup** 

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly)**ItemSubsystem 

### Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)** 

# SYSTEM & SUBSYSTEM DESCRIPTION **NEW TECHNOLOGY GENERAL PART INFORMATION:**

**2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV**

**(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)**

Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly) Tooling** 

**(x1000)** 

# Technology **Level:** Mild Hybrid, Start

- Stop Technology

**Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers



# Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

**443.84 $**  **49.07**

**$ 181.72** 

**$ 674.62** 

**$ 4.85** 

**$ 49.11** 

**$ 55.56** 

**$ 27.19** 

**$ 136.71** 

**$ 2.33** 

**$ 813.66** 

**$**

**-**

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**-**

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### -

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**$ SUBSYSTEM ROLL-UP** 

09000064810e7549.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:3 of 6 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/21/2012

DRAFT



# 140300 High Voltage Traction Battery **Subsy stem** 

1 **00**

2 **01**

3 **03**

4 **70**

5 **75**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

End Item

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

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

**- $** 

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**$ 2.27** 

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**$ 443.31** 

**$ 46.80** 

**$ 181.11** 

**$ 671.22** 

**$ 4.85** 

**$ 49.11** 

**$ 55.56** 

**$ 27.19** 

**$ 136.71** 

**$ 2.33** 

**$ 810.26** 

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# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE** 

Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)** Markup

**Total Markup**

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly) Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM** Markup

**Total Markup**

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly) Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM System** 

**ED&T/R&D**

**(x1000) Tooling** 

**(x1000) System** 

**ED&T/R&D**

**(x1000) Tooling** 

**(x1000) Investment** 

**(X1000)**



### 6 **80**

7 **85**

8 **90**

9 **99**

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### 0 **0**

**-**

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### 09000064810e7549.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:4 of 6 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/21/2012

DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

End Item

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

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

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE** 

Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)** Markup

**Total Markup**

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly) Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM** Markup

**Total Markup**

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly) Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM System** 

**ED&T/R&D**

**(x1000) Tooling** 

**(x1000) System** 

**ED&T/R&D**

**(x1000) Tooling** 

**(x1000) Investment** 

**(X1000)**



### - **$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### ###### **49.07 $**  **181.72**

**$ 674.62** 

**$ 4.85** 

**$ 49.11** 

**$ 55.56** 

**$ 27.19** 

**$ 136.71** 

**$ 2.33** 

**$ 813.66** 

**$**

**-**

**$**

**-**

**$**



### 09000064810e7549.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:5 of 6 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/21/2012

DRAFT



# 140300 High Voltage Traction Battery **Subsy stem** 

1 **00**

2 **01**

3 **03**

4 **70**

5 **75**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

**- $** 

**- $** 

**- $** 

**- $** 

**- $**  **Investment(X1**

**000)**



### 6 **80**

7 **85**

8 **90**

9 **99**

0 **0**

0 **0**

0 **0**

0 **0**

0 **0**

0 **0**

0 **0**

0 **0**

0 **0**

0 **0 -** 

**$**

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 



### 0 **0**

**-**

**$**



### 09000064810e7549.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:6 of 6 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/21/2012

DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

**Investment(X1**

**000)**

**- $** 



### 09000064810e7549.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:1 of 4 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/21/2012

DRAFT

Material Labor Burden End Item

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



### 0

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$** 

# 140300 High Voltage Traction Battery **Subsy stem** 

1 **00 Assembly of High Voltage Traction Battery Subsystem**  **0.53 $**  **2.27**

**$ 0.60** 

**$ 3.40** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 3.40** 

**$**

**-**

**$**



### A Assembly of High Voltage Traction Battery Subsystem 14 03 00

- N0402

- 01 1 Full 1 

### 0.53 $ 2.27

$ 0.60

$ **3.40**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **3.40**

**$**

**-**

**$**



### 2 **01 Traction Battery**  **443.31 $**  **46.80**

**$ 181.11** 

**$ 671.22** 

**$ 4.85** 

**$ 49.11** 

**$ 55.56** 

**$ 27.19** 

**$ 136.71** 

**$ 2.33** 

**$ 810.26** 

**$**

**-**

**$**



### A Generator Battery Assembly 14 03 01

- N0402

- 01 1 Full 1 

### $443.31 46.80 $ 181.11

$ **671.22**

**$** 4.85

$ 49.11

$ 55.56

$ 27.19

$ **136.71**

**$** 2.33

$ **810.26**

**$**

**-**

**$ Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly) Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM System** 

**ED&T/R&D**

**(x1000)** 

### Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor

(Default =1) **Total Markup**

**Cost**

**(Component/**

**Assembly)** 

# NEW TECHNOLOGY GENERAL PART INFORMATION:

**2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV**

**(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)**ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**

MarkupAssembly



### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)**SubassemblyComponentSub-Subsystem 

# Technology **Level:** Mild Hybrid, Start

- Stop Technology

**Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers



# Study Case#: N0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

3 **03 Power Cabling > 12V Dc** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 4 **70 Pipes, Hoses, Ducting** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 5 **75 Brackets** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 6 **80 Boltings** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

B Bolt- Battery Mount, Side 

### 14 03 80

- N0402

- 02 2 Full 1 PIA to Assembly of High Voltage

Traction Battery Subsystem 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### C Nut - Closeout Trim to Battery Interface 14 03 80

- N0402

- 03 2 Full 1 PIA to Assembly of High Voltage

Traction Battery Subsystem



### D Nut - V High Voltage W ire Harness Assembly to Battery 14 03 80

- N0402

- 04 1 Full 1 PIA to Assembly of High Voltage

Traction Battery Subsystem



### E Nut - V High Voltage W ire Harness Ass'y Shielding Ground 14 03 80

- N0402

- 05 1 Full 1 PIA to Assembly of High Voltage

Traction Battery Subsystem



### F Nut - V Ground Strap, Rear Battery (Battery Stud) 14 03 80

- N0402

- 06 1 Full 1 PIA to Assembly of High Voltage

Traction Battery Subsystem



### G Bolt, Battery Disconnect Closeout Cover 14 03 80

- N0402

- 07 1 Full 1 PIA to Assembly of High Voltage

Traction Battery Subsystem



### 7 **85 Sealing Elements** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 8 **90 Bearings Elements Misc** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$** 

### $ **$** $ **$ $** 



### 9 **99 Miscellaneous** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 09000064810e7549.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:2 of 4 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/21/2012

DRAFT

Material Labor Burden End Item

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

**Packaging**

**Cost**

**(Component**

**/ Assembly) Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM System** 

**ED&T/R&D**

**(x1000)** 

### Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor

(Default =1) **Total Markup**

**Cost**

**(Component/**

**Assembly)** 

# NEW TECHNOLOGY GENERAL PART INFORMATION:

**2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV**

**(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)**ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**

MarkupAssembly



### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)**SubassemblyComponentSub-Subsystem 

# Technology **Level:** Mild Hybrid, Start

- Stop Technology

**Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers



# Study Case#: N0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 10 443.84 $ 49.07

$ 181.72

$ **674.62**

**$** 4.85

$ 49.11

$ 55.56

$ 27.19

$ **136.71**

**$** 2.33

$ **813.66**

**$**

**-**

**$**



### NOTES:



## 1. **No** Complete Subsystem Quote

(Yes/No)

**= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of**

**the competing technology**

09000064810e7549.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:3 of 4 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/21/2012

DRAFT

0



# 140300 High Voltage Traction Battery **Subsy stem** 

1 **00 Assembly of High Voltage Traction Battery Subsystem** 

A Assembly of High Voltage Traction Battery Subsystem 14 03 00

- N0402

- 01 1 Full 1



### 2 **01 Traction Battery** 

A Generator Battery Assembly 14 03 01

- N0402

- 01 1 Full 1 

### Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor

(Default =1) 

# NEW TECHNOLOGY GENERAL PART INFORMATION:

**2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV**

**(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)**ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Mild Hybrid, Start

- Stop Technology

**Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers



# Study Case#: N0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$ Investment** 

**(X1000) Tooling** 

**(x1000)**



### 3 **03 Power Cabling > 12V Dc** 

4 **70 Pipes, Hoses, Ducting** 

5 **75 Brackets** 

6 **80 Boltings** 

B Bolt- Battery Mount, Side 

### 14 03 80

- N0402

- 02 2 Full 1 PIA to Assembly of High Voltage

Traction Battery Subsystem



### C Nut - Closeout Trim to Battery Interface 14 03 80

- N0402

- 03 2 Full 1 PIA to Assembly of High Voltage

Traction Battery Subsystem



### D Nut - V High Voltage W ire Harness Assembly to Battery 14 03 80

- N0402

- 04 1 Full 1 PIA to Assembly of High Voltage

Traction Battery Subsystem



### E Nut - V High Voltage W ire Harness Ass'y Shielding Ground 14 03 80

- N0402

- 05 1 Full 1 PIA to Assembly of High Voltage

Traction Battery Subsystem



### F Nut - V Ground Strap, Rear Battery (Battery Stud) 14 03 80

- N0402

- 06 1 Full 1 PIA to Assembly of High Voltage

Traction Battery Subsystem



### G Bolt, Battery Disconnect Closeout Cover 14 03 80

- N0402

- 07 1 Full 1 PIA to Assembly of High Voltage

Traction Battery Subsystem



### 7 **85 Sealing Elements** 

8 **90 Bearings Elements Misc**  **- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



### 9 **99 Miscellaneous**  **- $** 

**-**

**$**

**- $** 

**-**

**$**



### 09000064810e7549.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:4 of 4 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/21/2012

DRAFT

Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor

(Default =1) 

# NEW TECHNOLOGY GENERAL PART INFORMATION:

**2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV**

**(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)**ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Mild Hybrid, Start

- Stop Technology

**Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers



# Study Case#: N0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

10

**NOTES:**



## 1. **No** Complete Subsystem Quote

(Yes/No)

**= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of**

**the competing technology Investment** 

**(X1000) Tooling** 

**(x1000)**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



### 09000064810e7549.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:1 of 2 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/21/2012

DRAFT

Material Labor Burden End Item

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



### 0

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$** 

# 140300 High Voltage Traction Battery **Subsy stem** 

1 **00 Assembly of High Voltage Traction Battery Subsystem** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 2 **01 Traction Battery** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 3 **03 Power Cabling > 12V Dc** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$** 

# BASE TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)**SubassemblyComponentSub-Subsystem 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



### Name/Description Part Number Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor

(Default =1) **Net**

**Component/**

**Assembly**

**Cost Impact to**

**OEM System** 

**ED&T/R&D**

**(x1000)** Markup

**Total Markup**

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly)** 

# Technology **Level:** Mild Hybrid, Start

- Stop Technology

**Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers



# Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 4 **70 Pipes, Hoses, Ducting** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 5 **75 Brackets** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 6 **80 Boltings** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 7 **85 Sealing Elements** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 8 **90 Bearings Elements Misc** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 9 **99 Miscellaneous** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 10

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### NOTES:



## 1. **= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of**

**the competing technology** Complete Subsystem Quote

(Yes/No) 

## N

09000064810e7549.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:2 of 2 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/21/2012

DRAFT

0



# 140300 High Voltage Traction Battery **Subsy stem** 

1 **00 Assembly of High Voltage Traction Battery Subsystem** 

2 **01 Traction Battery** 

3 **03 Power Cabling > 12V Dc** QTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



### Name/Description Part Number Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor

(Default =1) 

# Technology **Level:** Mild Hybrid, Start

- Stop Technology

**Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers



# Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$ Investment** 

**(X1000) Tooling** 

**(x1000)**



### 4 **70 Pipes, Hoses, Ducting** 

5 **75 Brackets** 

6 **80 Boltings** 

7 **85 Sealing Elements** 

8 **90 Bearings Elements Misc** 

9 **99 Miscellaneous** 

10

**NOTES:**



## 1. **= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of**

**the competing technology** Complete Subsystem Quote

(Yes/No) 

## N **- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



### 09000064810e7549.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 1 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM Assembly, Mark-up Covered by ICM**



## System Description: **2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)** 

## Annual Component Volume: Shipping Method:

**Component Description: Install of Generator Battery Ass'y and Associated hardware into Vehicle**  

## Part Number: **140300-N0402-01** 

## We ekly Component Volume: Packaging Specification: **Not Applicable**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

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

1 1 Install of Generator Battery Ass'y and

Associated hardware into Vehicle 140300-N0402-01 **1** Load Battery into Vehicle OEM Assembly, Mark-up

Covered by ICM Not Applicable General Assembly-OEM VO Assembly, OEM, MC **138 1**  **1 1**  0.000 **$0.00 $97.48**  **$50.00 $50.00**  **$0.00 $0.70**  **$0.36 $1.07**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.07 $1.07**  **$0.00**

2 Install of Generator Battery Ass'y and

Associated hardware into Vehicle 140300-N0402-01 **1** Secure Battery to Sheet metal OEM Assembly, Mark-up

Covered by ICM Not Applicable General Assembly-OEM VO Assembly, OEM, LC **225 1**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.43**  **$0.07 $0.50**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.50 $0.50**  **$0.00**

3 Install of Generator Battery Ass'y and

Associated hardware into Vehicle 140300-N0402-01 **1** Connect wire harnesses to

battery. OEM Assembly, Mark-up

Covered by ICM Not Applicable General Assembly-OEM VO Assembly, OEM, LC **138 1**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.70**  **$0.11 $0.81**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.81 $0.81**  **$0.00**

Install of Generator Battery Ass'y and Secure battery closeout panel, OEM Assembly, Mark-up 

### 9,574

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Hybrid - Start-Stop Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

4 Install of Generator Battery Ass'y and

Associated hardware into Vehicle 140300-N0402-01 **1** connect battery control wire

harness. OEM Assembly, Mark-up

Covered by ICM Not Applicable General Assembly-OEM VO Assembly, OEM, LC **225 1**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.43**  **$0.07 $0.50**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.50 $0.50**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 2 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM Assembly, Mark-up Covered by ICM**



## System Description: **2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)** 

## Annual Component Volume: Shipping Method:

**Component Description: Install of Generator Battery Ass'y and Associated hardware into Vehicle**  

## Part Number: **140300-N0402-01** 

## We ekly Component Volume: Packaging Specification: **Not Applicable**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Hybrid - Start-Stop Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### C 

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

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 3 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM Assembly, Mark-up Covered by ICM**



## System Description: **2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)** 

## Annual Component Volume: Shipping Method:

**Component Description: Install of Generator Battery Ass'y and Associated hardware into Vehicle**  

## Part Number: **140300-N0402-01** 

## We ekly Component Volume: Packaging Specification: **Not Applicable**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Hybrid - Start-Stop Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 1A Bolt- Battery Mount, Side **2** S **$0.00** $0.12 **$0.00 $0.24**  **$0.24**

2 2A Nut - Closeout Trim to Battery Interface **2** S **$0.00** $0.03 **$0.00 $0.06**  **$0.06**

3 3A Nut - V High Voltage Wire Harness Assembly to

Battery **1** S **$0.00** $0.07 **$0.00 $0.07**  **$0.07**

4 4A Nut - V High Voltage Wire Harness Ass'y

Shielding Ground **1** S **$0.00** $0.04 **$0.00 $0.04**  **$0.04** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to

T1 or OEM for Final or Sub

- Assembly. In addition component material cost is

accounted for in T1 quote sheet. Thus component cost will only be included for Shielding Ground

5 5A Nut - V Ground Strap, Rear Battery (Battery

Stud) **1** S **$0.00** $0.04 **$0.00 $0.04**  **$0.04**

6 6A Bolt, Battery Disconnect Closeout Cover **1** S **$0.00** $0.08 **$0.00 $0.08**  **$0.08**

7 **$0.00** $0.00 **$0.00 $0.00**  **$0.00**

8 **$0.00** $0.00 **$0.00 $0.00**  **$0.00**

9 **$0.00** $0.00 **$0.00 $0.00**  **$0.00**

10 **$0.00** $0.00 **$0.00 $0.00**  **$0.00**

11 **$0.00** $0.00 **$0.00 $0.00**  **$0.00**

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

**Material** 

### accounted for in T1 quote sheet. Thus component cost will only be included for

Mark

- up Calculations.

"Alpha

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

Supplier for Subassembly.

**$0.53**

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

**Mark-up $3.40** 

**T1 or OEM Total Manufacturing Cost: $0.53**  **$2.27 $0.60**  **$3.40 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$3.40**

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

----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%

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

----- ----- ----- **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**Base Cost Impact to Vehicle: $0.53**  **$2.27 $0.60**  **$3.40 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$3.40 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $3.40**  **3 1** 



### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 4 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM Assembly, Mark-up Covered by ICM**



## System Description: **2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)** 

## Annual Component Volume: Shipping Method:

**Component Description: Install of Generator Battery Ass'y and Associated hardware into Vehicle**  

## Part Number: **140300-N0402-01** 

## We ekly Component Volume: Packaging Specification: **Not Applicable**



## Component Quote Level: Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Hybrid - Start-Stop Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment**

**(%) Total # of** 

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447**  

### PACKAGING CALCULATIONS:

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers: **Reference Packaging Database for Additional Information**

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

**Packaging**

**Cost per**

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



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



### Packaging Cost Total: **$0.000** 

### Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 5 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

1 Install of Generator Battery Ass'y and

Associated hardware into Vehicle 140300-N0402-01

Install of Generator Battery Ass'y and

Associated hardware into Vehicle 140300-N0402-01

Install of Generator Battery Ass'y and

Associated hardware into Vehicle 140300-N0402-01

Install of Generator Battery Ass'y and



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.70 $0.36**  **$1.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Semi automated loading of battery into vehicle - single operator, ergo arm assist **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- 1 1 26 **1.0 1.0** 

**$0.43 $0.07**  **$0.50 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Seven attachments in total (5 common with seat) only include assembly cost for 2. Operator hand start

and manual rundown. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- 1 1 16 **1.0 1.0** 

**$0.70 $0.11**  **$0.81 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Secure high voltage wire harness leads (x2) and grounding strap to battery (x1). Manual assembly, hand

start fastener, auto run-down. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- 1 1 26 **1.0 1.0**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

Install of Generator Battery Ass'y and

Associated hardware into Vehicle 140300-N0402-01



## Purchase Part - High Impact Item (Full Cost Mapping) **$0.43 $0.07**  **$0.50 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Manual secure battery closeout panel, run fastener, make battery control module wire harness connection. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- 1 1 16 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 



## Purchase Part - High Impact Item (Full Cost Mapping)

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 6 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 7 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



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

1A Bolt- Battery Mount, Side

2A Nut - Closeout Trim to Battery Interface

3A Nut - V High Voltage Wire Harness Assembly to

Battery

4A Nut - V High Voltage Wire Harness Ass'y

Shielding Ground 

### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.24**

**$0.06**

**$0.07**

**$0.04** Shielding Ground

5A Nut - V Ground Strap, Rear Battery (Battery

Stud)

6A Bolt, Battery Disconnect Closeout Cover **$0.04**

**$0.08**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

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

**Total**

**$2.27 $0.60**  **$3.40 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$3.40 2** 



### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 8 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 9 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

1 Install of Generator Battery Ass'y and

Associated hardware into Vehicle 140300-N0402-01

Install of Generator Battery Ass'y and

Associated hardware into Vehicle 140300-N0402-01

Install of Generator Battery Ass'y and

Associated hardware into Vehicle 140300-N0402-01

Install of Generator Battery Ass'y and



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**138 26.00**  1.00

**225 16.00**  1.00

**138 26.00**  1.00

Install of Generator Battery Ass'y and

Associated hardware into Vehicle 140300-N0402-01



## Purchase Part - High Impact Item (Full Cost Mapping) **225 16.00**  1.00

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



## Purchase Part - High Impact Item (Full Cost Mapping)

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 10 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 11 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



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

1A Bolt- Battery Mount, Side

2A Nut - Closeout Trim to Battery Interface

3A Nut - V High Voltage Wire Harness Assembly to

Battery

4A Nut - V High Voltage Wire Harness Ass'y

Shielding Ground**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

Shielding Ground

5A Nut - V Ground Strap, Rear Battery (Battery

Stud)

6A Bolt, Battery Disconnect Closeout Cover



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 12 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:1 of 4 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/21/2012

DRAFT

Material Labor Burden End Item

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

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$



# 03 **Generator Battery**

**A ssembly**  **Roll-up**

**03 Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)** 

A V Battery Disconnect Unit # 03 03

- N0402

- 01 $37.24 $0.99 $4.64 **$42.87** $0.30 $3.00 $3.43 $1.71 **$8.44** $0.00



## A1 V Chassis - Battery Disconn # 03 03

- N0402

- 02



## A2 V Module - Auto Batt. # 03 03

- N0402

- 06



## A3 V Screw - Batt. Discharge Mod. # 03 #

- N0402

- 08



## A4 V Bus Bar - Auto Discharge # 03 03

- N0402

- 07



## A5 V Nut - Bus Bar Auto Discharge # 03 #

- N0402

- 09



## A6 V Stud - Fusable Link # 03 03

- N0402

- 08 **Total**

**Packaging**

**Cost**

**(Component**

**/ Assembly)** 

### Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor

(Default =1) **Total Markup**

**Cost**

**(Component/**

**Assembly)** 

# NEW TECHNOLOGY GENERAL PART INFORMATION:

**Mild Series Gasoline Hybrid**ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**

MarkupAssembly



### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)**SubassemblyComponentSub-Subsystem 

# Technology **Level:** Mild Series Gasoline Hybrid



# Vehicle Class: Mid to Large Size Passenger Vehicle, 4

- 6 Passengers



# Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )

A6 V Stud - Fusable Link # 03 03

- N0402

- 08



## A7 V Fuse - Battery Disconnect # 03 03

- N0402

- 09



## A8 V Nut Fusable link # 03 #

- N0402

- #



## A9 V Signal Module - Battery # 03 03

- N0402

- #



## A10 V Screw - Batt. Signal Module # 03 #

- N0402

- #



## B V Harness-Battery Pack # 03 03

- N0402

- # $98.89 $0.00 $0.00 **$98.89** $0.69 $6.92 $7.91 $3.96 **$19.48** $0.00



## B1 V Harness-Battery Pack # 03 03

- N0402

- #



## B2 V Harness Batt. Pack Signal # 03 03

- N0402

- #



## B3 V Harness- Interface # 03 03

- N0402

- #



## B4 V Battery Control PCB # 03 03

- N0402

- #



## C V Battery Module - NiMH # 03 03

- N0402

- #



## C1 V Cell Electrode W rapper - NMH (60 units - individual stacks) # 03 03

- N0402

- # $238.76 $14.78 $36.49 **$290.02** $2.03 $20.30 $23.20 $11.60 **$57.13** $0.00



## C2 V Batt Mod (ex-Cells) 0303C # 03 03

- N0402

- # $41.95 $24.50 $117.60 **$184.04** $1.29 $12.88 $14.72 $7.36 **$36.26** $2.33



## D V Cable-Positive Battery Short # 03 03

- N0402

- #



## E V Cable-Positive Battery 1-4 # 03 03

- N0402

- #



## F V Cable-Positive Battery # 03 03

- N0402

- #



## G V Cable-Negative Cable # 03 03

- N0402

- #



## 05 **Cooling Fan**

A V Fan - Battery Pack Cooling # 03 05

- N0402

- 01 $14.90 $1.78 $6.85 **$23.52** $0.16 $1.65 $1.88 $0.94 **$4.63** $0.00



## A1 V Housing - Battery Fan # 03 06

- N0402

- #



## A2 V Fan Assy - Batt. Cooling # 03 05

- N0402

- 02



## A3 V Screw - Batt. Fan to Housing # 03 #

- N0402

- #



## A4 V Label - Bar Code Batt. Fan # 03 #

- N0402

- 06



## A5 V Label - Batt. Fan W arning # 03 #

- N0402

- 07



## A6 V Seal - BAtt. Fan - Case # 03 #

- N0402

- 01



## 06 **Covers**

A V Cover- Battery Terminal # 03 06

- N0402

- #

09000064810e7549.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:2 of 4 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/21/2012

DRAFT

Material Labor Burden End Item

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

**Packaging**

**Cost**

**(Component**

**/ Assembly)** 

### Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor

(Default =1) **Total Markup**

**Cost**

**(Component/**

**Assembly)** 

# NEW TECHNOLOGY GENERAL PART INFORMATION:

**Mild Series Gasoline Hybrid**ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**

MarkupAssembly



### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)**SubassemblyComponentSub-Subsystem 

# Technology **Level:** Mild Series Gasoline Hybrid



# Vehicle Class: Mid to Large Size Passenger Vehicle, 4

- 6 Passengers



# Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )

B V Battery Pack Lid # 03 06

- N0402

- # $4.50 $0.99 $4.02 **$9.50** $0.12 $1.31 $1.38 $0.52 **$3.32** $0.00



## B1 V Battery Pack Lid # 03 06

- N0402

- #



## B2 V Velcro Patch # 03 #

- N0402

- 02



## B3 V Label - 36V Caution # 03 #

- N0402

- 03



## B4 V Label - Bar Code # 03 #

- N0402

- 04



## B5 v Label - NiMH Recycle # 03 #

- N0402

- 05



## B6 V Clip - Rosebud W H # 03 #

- N0402

- #



## C V Battery Pack Service Door # 03 06

- N0402

- # $0.64 $0.64 $1.57 **$2.85** $0.03 $0.40 $0.40 $0.14 **$0.97** $0.00



## C1 V Battery Pack Service Door # 03 06

- N0402

- #



## 75 **Brackets**

A V Tray - Battery # 03 75

- N0402

- 01 $6.44 $3.13 $9.96 **$19.53** $0.22 $2.65 $2.64 $0.96 **$6.47** $0.00



## A1 V Tray - Battery # 03 75

- N0402

- 02 

## V Tray - Battery

A2 V Bracket # 1 - Batt. Tray # 03 75

- N0402

- 05



## A3 V Bracket #2 - Battery Tray # 03 75

- N0402

- 07



## A4 V Bracket #3 - Battery Tray # 03 75

- N0402

- #



## A5 V Bracket #4- Battery Tray # 03 75

- N0402

- #



## A6 V Bracket # 5- Battery Tray # 03 75

- N0402

- #



## A7 V Bracket #6 - Battery Tray # 03 75

- N0402

- #



## A8 V Clip - Rosebud W H # 03 #

- N0402

- 07



## 80 **Boltings / Fasteners**

A V Screw- Batt. Disconn.Unit to # 03 #

- N0402

- #



## B V Screw- Batt. Disconn.Unit to # 03 #

- N0402

- #



## C V Screw-Batt. Disconn SW Assy # 03 #

- N0402

- #



## D V Screw - Batt. Harn. Integral # 03 #

- N0402

- #



## E V Nut - Auto Discharge Unit post # 03 #

- N0402

- #



## F V Screw - Battery module - tray # 03 #

- N0402

- #



## G V Tie W rap # 03 #

- N0402

- #



## H V Nut Cable to Battery Terrminal # 03 #

- N0402

- #



## I V Screw - Battery Pack Lid # 03 #

- N0402

- #



## J V Screw- Battery Pack Cooling # 03 #

- N0402

- #



## K V Screw Battery Pack Service # 03 #

- N0402

- #

$443.31 46.80 $ 181.11

$ **671.22**

**$** 4.85

$ 49.11

$ 55.56

$ 27.19

$ **136.71**

**$** 2.33

$

**NOTES:**



## 1. Complete Subsystem Quote

(Yes/No)

**= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of the competing technology**

09000064810e7549.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:3 of 4 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/21/2012

DRAFT



# 03 **Generator Battery**

**A ssembly**  **Roll-up**

**03 Engine Electrical Systems (including Wiring Harnesses, Earth Straps, Ignition Harness, Coils, Sockets)** 

A V Battery Disconnect Unit # 03 03

- N0402

- 01



## A1 V Chassis - Battery Disconn # 03 03

- N0402

- 02



## A2 V Module - Auto Batt. # 03 03

- N0402

- 06



## A3 V Screw - Batt. Discharge Mod. # 03 #

- N0402

- 08



## A4 V Bus Bar - Auto Discharge # 03 03

- N0402

- 07



## A5 V Nut - Bus Bar Auto Discharge # 03 #

- N0402

- 09



## A6 V Stud - Fusable Link # 03 03

- N0402

- 08 Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor

(Default =1) 

# NEW TECHNOLOGY GENERAL PART INFORMATION:

**Mild Series Gasoline Hybrid**ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Mild Series Gasoline Hybrid



# Vehicle Class: Mid to Large Size Passenger Vehicle, 4

- 6 Passengers



# Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**



### - **$**

**-**

**$**

**-**

**$**

**-**

**$**

**$51.31 Net** 

**Component/**

**Assembly**

**Cost Impact to**

**OEM System** 

**ED&T/R&D**

**(x1000) Investment** 

**(X1000) Tooling** 

**(x1000)** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

A6 V Stud - Fusable Link # 03 03

- N0402

- 08



## A7 V Fuse - Battery Disconnect # 03 03

- N0402

- 09



## A8 V Nut Fusable link # 03 #

- N0402

- #



## A9 V Signal Module - Battery # 03 03

- N0402

- #



## A10 V Screw - Batt. Signal Module # 03 #

- N0402

- #



## B V Harness-Battery Pack # 03 03

- N0402

- #



## B1 V Harness-Battery Pack # 03 03

- N0402

- #



## B2 V Harness Batt. Pack Signal # 03 03

- N0402

- #



## B3 V Harness- Interface # 03 03

- N0402

- #



## B4 V Battery Control PCB # 03 03

- N0402

- #



## C V Battery Module - NiMH # 03 03

- N0402

- #



## C1 V Cell Electrode W rapper - NMH (60 units - individual stacks) # 03 03

- N0402

- #



## C2 V Batt Mod (ex-Cells) 0303C # 03 03

- N0402

- #



## D V Cable-Positive Battery Short # 03 03

- N0402

- #



## E V Cable-Positive Battery 1-4 # 03 03

- N0402

- #



## F V Cable-Positive Battery # 03 03

- N0402

- #



## G V Cable-Negative Cable # 03 03

- N0402

- #



## 05 **Cooling Fan**

A V Fan - Battery Pack Cooling # 03 05

- N0402

- 01



## A1 V Housing - Battery Fan # 03 06

- N0402

- #



## A2 V Fan Assy - Batt. Cooling # 03 05

- N0402

- 02



## A3 V Screw - Batt. Fan to Housing # 03 #

- N0402

- #



## A4 V Label - Bar Code Batt. Fan # 03 #

- N0402

- 06



## A5 V Label - Batt. Fan W arning # 03 #

- N0402

- 07



## A6 V Seal - BAtt. Fan - Case # 03 #

- N0402

- 01



## 06 **Covers $118.37** 

**$347.16**

**$222.63**

**$28.16**



## 06 **Covers**

A V Cover- Battery Terminal # 03 06

- N0402

- #

09000064810e7549.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page:4 of 4 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/21/2012

DRAFT

Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor

(Default =1) 

# NEW TECHNOLOGY GENERAL PART INFORMATION:

**Mild Series Gasoline Hybrid**ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Mild Series Gasoline Hybrid



# Vehicle Class: Mid to Large Size Passenger Vehicle, 4

- 6 Passengers



# Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )

B V Battery Pack Lid # 03 06

- N0402

- #



## B1 V Battery Pack Lid # 03 06

- N0402

- #



## B2 V Velcro Patch # 03 #

- N0402

- 02



## B3 V Label - 36V Caution # 03 #

- N0402

- 03



## B4 V Label - Bar Code # 03 #

- N0402

- 04



## B5 v Label - NiMH Recycle # 03 #

- N0402

- 05



## B6 V Clip - Rosebud W H # 03 #

- N0402

- #



## C V Battery Pack Service Door # 03 06

- N0402

- #



## C1 V Battery Pack Service Door # 03 06

- N0402

- #



## 75 **Brackets**

A V Tray - Battery # 03 75

- N0402

- 01



## A1 V Tray - Battery # 03 75

- N0402

- 02 **Net**

**Component/**

**Assembly**

**Cost Impact to**

**OEM System** 

**ED&T/R&D**

**(x1000) Investment** 

**(X1000) Tooling** 

**(x1000)** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

**$12.82**

**$3.82**

**$26.00**



## A1 V Tray - Battery # 03 75

- N0402

- 02



## A2 V Bracket # 1 - Batt. Tray # 03 75

- N0402

- 05



## A3 V Bracket #2 - Battery Tray # 03 75

- N0402

- 07



## A4 V Bracket #3 - Battery Tray # 03 75

- N0402

- #



## A5 V Bracket #4- Battery Tray # 03 75

- N0402

- #



## A6 V Bracket # 5- Battery Tray # 03 75

- N0402

- #



## A7 V Bracket #6 - Battery Tray # 03 75

- N0402

- #



## A8 V Clip - Rosebud W H # 03 #

- N0402

- 07



## 80 **Boltings / Fasteners**

A V Screw- Batt. Disconn.Unit to # 03 #

- N0402

- #



## B V Screw- Batt. Disconn.Unit to # 03 #

- N0402

- #



## C V Screw-Batt. Disconn SW Assy # 03 #

- N0402

- #



## D V Screw - Batt. Harn. Integral # 03 #

- N0402

- #



## E V Nut - Auto Discharge Unit post # 03 #

- N0402

- #



## F V Screw - Battery module - tray # 03 #

- N0402

- #



## G V Tie W rap # 03 #

- N0402

- #



## H V Nut Cable to Battery Terrminal # 03 #

- N0402

- #



## I V Screw - Battery Pack Lid # 03 #

- N0402

- #



## J V Screw- Battery Pack Cooling # 03 #

- N0402

- #



## K V Screw Battery Pack Service # 03 #

- N0402

- #

**NOTES:**



## 1. Complete Subsystem Quote

(Yes/No) **810.26 $** 

**-**

**$**

**-**

**$**

**-**

**$**



## 1. **= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of the competing technology**

09000064810e7549.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411

# After

Market

Price OEM

Cost

Estimate

1) Battery

Ty pe 1 895.35

$ 392.14

$

# 2) Battery Ty pe 2 1,074.42

$ N/A

3) Control module 317.87 $ N/A

4) Control module Cover 77.60 $ 3.82

$

5) Fan 81.09 $ 28.16

$

6) Negative cable 75.49 $ $3.25

7) Harness No Price N/A

# Ratio

2.3

# 20.3

2.9

23.2

# Indented Bill of Materials

**V Elec Power Supply Sy**  **stem**

**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost Weight**  **Piece Cost Weight (Total)** 



# . **(Total)**



# . **V Battery Subsy**  **stem V Battery**  

# 56.7351 lb

. **Subsy stem** 



# . **1 V Tray**  **- Battery V Tray**  **- Battery 1**  **Steel Stamping $0.00**  **7.4890 lb $0.00** 



# . **2 V Tray**  **- Battery V Tray**  **- Battery 1**  **Steel Stamping $0.00**  **4.1936 lb $0.00** 



# . **3 V Tray**  **- Battery V Tray**  **- Battery 1**  **Steel Stamping $0.00**  **4.1600 lb**



# . **4** V Tray - Battery V Tray - Battery **1** Steel Stamping **$0.00 4.1600 lb** 



# . 3 v W eld Nut - Projection v W eld Nut - 12 $0.00 0.0028 lb



# . Projection



# . **2 V Bracket # 1 - Batt. Tray**  **v Bracket # 1 - 1**  **Stamped Steel $0.00**  **0.1210 lb $0.00** 



# . **Batt. Tray**



# . **3** v Bracket # 1 - Batt. Tray v Bracket # 1 - **1** Stamped Steel **$0.00 0.1210 lb** 



# . Batt. Tray



# . **2 V Bracket #2 - Battery**  **Tray V Bracket #2 -**  **1 Steel Low**  **$0.00 0.9024 lb**  **$0.00**



# . **Battery Tray**  **Carbon Draw**



# . **Quality**



# . **3 V Bracket #2 - Battery**  **Tray V Bracket #2 -**  **1 Steel Low**  **$0.00 0.7084 lb**  **V Bracket #2 - Battery V Bracket #2 -**  **Steel Low 0.7084 lb** 



# . **Battery Tray**  **Carbon Draw**



# . **Quality**



# . **4** V Bracket #2 - Battery Tray V Bracket #2 - **1** Steel Low **$0.00 0.7000 lb** 



# . Battery Tray Carbon Draw



# . Quality



# . 4 v W eld Nut - Projection v W eld Nut - 3 $0.00 0.0028 lb



# . Projection



# . **3 V Hinge Bracket - A**  **ccess Door V Hinge Bracket**  **2 Steel Low**  **$0.00 0.0750 lb** 



# . **- A ccess Door**  **Carbon Draw**



# . **Quality**



# . **4** V Hinge Bracket - Access Door V Hinge Bracket **2** Steel Low **$0.00 0.0375 lb** 



# . - Access Door Carbon Draw



# . Quality



# . **3 V Bracket - Weld Stud**  **V Bracket - 1**  **Steel Low $0.00**  **0.0348 lb**



# . **Weld Stud Carbon Draw** 



# . **Quality**



# . **4** V Bracket - W eld Stud V Bracket - W eld **1** Steel Low **$0.00 0.0348 lb** 



# . Stud Carbon Draw



# . Quality

# . 3 V W eld Stud V W eld Stud 1 Commodity $0.00 0.0092 lb



# . Pricing



# . **2 V Bracket #3 - Battery**  **Tray V Bracket #3 -**  

# 1 **$0.00 0.5116 lb**  **$0.00**



# . **Battery Tray** 



# . **3 V Bracket #3 - Battery**  **Tray V Bracket #3 -**  **1 $0.00**  **0.4256 lb**



# . **Battery Tray** 



# . **4** V Bracket #3 - Battery Tray V Bracket #3 - **1 $0.00**  **0.4256 lb**



# . Battery Tray



# . **3 V Bracket - Stand Off**  **V Bracket - 1**  **Steel Low $0.00**  **0.0420 lb**



# . **Stand Off Carbon Draw** 



# . **Quality**



# . **4** V Bracket - Stand Off V Bracket - **1** Steel Low **$0.00 0.0420 lb** 



# . Stand Off Carbon Draw



# . Quality



# . **3 V Bracket - Weld Stud**  **V Bracket - 1**  **Steel Low $0.00**  **0.0348 lb**



# . **Weld Stud Carbon Draw** 



# . **Quality**



# . **4** V Bracket - W eld Stud V Bracket - W eld **1** Steel Low **$0.00 0.0348 lb** 



# . Stud Carbon Draw



# . Quality



# . 3 V W eld Stud V W eld Stud 1 Commodity $0.00 0.0092 lb



# . Pricing



# . **2 V Bracket #4- Battery**  **Tray V Bracket #4-**  

# 1 **$0.00 0.2130 lb**  **$0.00 V Bracket #4- Battery**  **V Bracket #4-** 

# 0.2130 lb



# . **Battery Tray** 



# . **3** V Bracket #4- Battery Tray V Bracket #4- **1 $0.00**  **0.2130 lb**



# . Battery Tray



# . **2 V Bracket # 5- Battery**  **Tray V Bracket # 5-**  

# 1 Steel Low **$0.00 0.5116 lb**  **$0.00**



# . **Battery Tray**  **Carbon Draw**



# . **Quality**



# . **3 V Bracket # 5- Battery**  **Tray V Bracket # 5-**  **1 Steel Low**  **$0.00 0.4256 lb** 



# . **Battery Tray**  **Carbon Draw**



# . **Quality**



# . **4** V Bracket # 5- Battery Tray V Bracket # 5- **1** Steel Low **$0.00 0.4256 lb** 



# . Battery Tray Carbon Draw



# . Quality



# . **3 V Bracket - Stand Off**  **V Bracket - 1**  **Steel Low $0.00**  **0.0420 lb**



# . **Stand Off Carbon Draw** 



# . **Quality**



# . **4** V Bracket - Stand Off V Bracket - **1** Steel Low **$0.00 0.0420 lb** 



# . Stand Off Carbon Draw



# . Quality



# . **3 V Bracket - Weld Stud**  **V Bracket - 1**  **Steel Low $0.00**  **0.0348 lb**

# . **Weld Stud Carbon Draw** 



# . **Quality**



# . 4 V Bracket - W eld Stud V Bracket - W eld 

# 1 Steel Low 

# $0.00 0.0348 lb



# . Stud Carbon Draw



# . Quality



# . 3 V W eld Stud V W eld Stud 1 Commodity $0.00 0.0092 lb



# . Pricing



# . **2 V Bracket #6 - Battery**  **Tray V Bracket #6 -**  

# 1 Steel Low **$0.00 1.0336 lb**  **$0.00**



# . **Battery Tray**  **Carbon Draw**



# . **Quality**



# . **3 V Bracket #6 - Battery**  **Tray V Bracket #6 -**  **1 Steel Low**  **$0.00 1.0000 lb** 



# . **Battery Tray**  **Carbon Draw**



# . **Quality**



# . **4** V Bracket #6 - Battery Tray V Bracket #6 - **1** Steel Low **$0.00 1.0000 lb** 



# . Battery Tray Carbon Draw



# . Quality



# . 3 v W eld Nut - Projection v W eld Nut - 12 $0.00 0.0028 lb



# . Projection



# . **2 V Clip - Rosebud WH**  **V Clip - Rosebud** 

# 1 Polypropylene **$0.00 0.0022 lb**  **$0.00**



# . WH



# . **1 V Battery**  **Disconnect Unit**

**V Battery 1**  **$0.00 1.5714 lb**  **$0.00**



# . **Disconnect Unit**



# . **2 V Chassis - Battery**  **Disconn Unit V Chassis -**  **1 AB**  **S $0.00**  **0.7500 lb $0.00**  **V Chassis - Battery**

**Disconn Unit V Chassis -**  **0.7500 lb**



# . **Battery Disconn** 



# . **Unit**



# . **3 V Stud - Positive Terminal**  **V Stud - Postive 1**  **OVERMOLDED STEEL $0.00**  **0.0000 lb**



# . **Terminal**



# . **3 V Stud - Negative Terminal**  **V Stud - Negative 1**  **OVERMOLDED STEEL $0.00**  **0.0000 lb**



# . **Terminal**



# . **3** V Chassis - Battery Disconn Unit V Chassis - **1** ABS **$0.00 0.7500 lb** 



# . Battery Disconn



# . Unit



# . **2 V Module - A**  **uto Batt. Discharge V Module - A**  **uto 1**  **$0.00 0.5437 lb**  **$0.00**



# . **Batt. Discharge**



# . **2** V Screw - Battery Discharge Mod. V Screw - Batt. **2 $0.00**  **0.0082 lb $0.00** 



# . Discharge Mod.



# . 2 V Bus Bar - Auto Discharge V Bus Bar - Auto 1 Copper $0.00 0.0471 lb $0.00



# . Discharge



# . 2 V Nut - Bus Bar Auto Discharge V Nut Cable to 1 $0.00 0.0154 lb $0.00



# . Battery Terrminal



# . 2 V Stud - Fusable Link V Stud - Fusable 1 $0.00 0.0000 lb $0.00



# . Link

# . **2 V Fuse - Battery**  **Disconnect Box V Fuse -**  

# 1 **$0.00 0.0207 lb**  **$0.00**



# . **BA ttery** 



# . **Disconnect Box**



# . **2** V Nut Fusable link V Nut Fusable **1 $0.00**  **0.0188 lb $0.00** 



# . link



# . **2 V Signal Module - Battery**  **V Signal 1**  **$0.00 0.1565 lb**  **$0.00**



# . **Module -**



# . **Battery**



# . **2** V Screw - Batt. Signal Module V Screw - Batt. **2** Steel **$0.00 0.0014 lb**  **$0.00**



# . Signal Module



# . 1 V Screw- Batt. Disconn.Unit to Tray V Screw- Batt. 3 $0.00 0.0063 lb $0.00



# . Disconn.Unit to



# . Tray



# . 1 V Screw- Batt. Disconn.Unit to Tray Bracket V Screw- Batt. 1 $0.00 0.0048 lb $0.00



# . Disconn.Unit to



# . Tray Bracket



# . **1 V Harness-Battery**  **Pack A ssembly**  **V 1**  **$0.00 1.9828 lb**  **$0.00**



# . **Harness-**



# . **Battery Pack** 



# . **As sembly** 



# . **2 V Harness-Battery**  **Pack A ssembly**  **V 1**  **$0.00 0.8450 lb**  **$0.00**



# . **Harness-**



# . **Battery Pack** 



# . **As sembly** 



# . **2 V Harness Batt. Pack Signal**  **V Harness Batt. 1**  **$0.00 0.4650 lb**  **$0.00**



# . **Pack Signal**



# . **2 V Harness- Interface**  **V Harness 1**  **$0.00 0.4300 lb**  **$0.00**



# . **Interface**



# . **2 V Battery**  **Control PCB A**

**ssembly V Battery**  **1 $0.00**  **0.2428 lb $0.00** 



# . **Control PCB**



# . **As sembly** 



# . **1** V Screw-Batt. Disconn SW Assy V Screw-Batt. **3 $0.00**  **0.0010 lb $0.00** 



# . Disconn SW



# . Assy



# . 1 V Screw - Batt. Harn. Integral PCB V Screw - Batt. 5 $0.00 0.0014 lb $0.00



# . Harn. Integral



# . PCB -



# . 1 V Nut - Auto Discharge Unit post V Nut - Auto 2 $0.00 0.0065 lb $0.00



# . Discharge Unit



# . post



# . **1 V Battery**  **Module - NMH V Battery**  **3 Nickel Metal**  **$0.00 12.8451 lb**  **$0.00**



# . **Module - NMH Hy**  **dride**

# .

. **2 V Carrier - Battery**  **Module V Carrier -**  

# 1 **Galvinized Steel** 

# $0.00 **1.6658 lb $0.00** 



# . **Battery Module** 



# . **3 V Chassis Side Panel - Batt. Module**  **V Chassis Side 2**  **$0.00 0.7660 lb** 



# . **Panel - Batt.**



# . **Module**



# . **4** V Chassis Side Panel- Battery Disconn Unit V Chassis Side **1 $0.00**  **0.7660 lb**



# . Panel - Batt.



# . Module



# . **3 V Straps- Battery**  **Module Chassis V Straps-**  **6 $0.00**  **0.0223 lb**



# . **Battery Module** 



# . **chassis**



# . **4** V Straps- Battery Module Chassis V Straps- **1 $0.00**  **0.0223 lb**



# . Battery Module



# . chassis



# . **2 V Battery**  **- NiMH V Battery** 

**- 2**  **$0.00 5.1000 lb**  **$0.00**



# . **NiMH**



# . **3 V Battery**  **Cell Case V Battery**  **Cell 1**  **Poly propy**  **lene $0.00**  **0.0000 lb**



# . **Case**



# . **4 V Battery**  **Cell Case Lid V Battery**  **Cell 1**  **$0.00 0.0000 lb** 



# . **Case Lid**



# . **4 V Battery**  **Cell Case Outer Walls**

**V Battery**

**Cell 1**  **$0.00 0.0000 lb** 



# . **Case Outer**



# . **Walls**



# . **4 V Battery**  **Cell Case Terminal Carrier**

**V Battery**

**Cell 1**  **$0.00 0.0000 lb** 



# . **Terminal**



# . **Carrier**



# . **5 V Battery**  **Cell Case Terminal Carrier**

**V Battery**

**Cell 1**  **# 0.0000 lb** 



# . **Terminal**



# . **Carrier**



# . **6** V Battery Cell Case Terminal Carrier V Battery Cell **1 #**  **0.0000 lb**



# . Terminal Carrier



# . **4 V Battery**  **Cell Case Floor**

**V Battery**

**Cell 1**  **PPE PS 10 GF $0.00**  **0.0000 lb**



# . **Case Floor**



# . **2 V Separator - Battery**  **Chassis V Separator -**  **2 Al**  **uminum $0.00**  **0.3300 lb $0.00** 



# . **Battery Chassis** 



# . **3** V Separator - Battery Chassis V Separator - **2** Aluminum **$0.00 0.1650 lb** 



# . Battery Chassis



# . **2 V Sensor - Battery**  **Temp V Sensor -**  **1 $0.00**  **0.0115 lb $0.00** 



# . **Battery Temp** 



# . **2 VTerminal Post Bracket - Battery**  **V Pos Terminal** 

# 1 **Stainless Steel** 

# $0.00 **0.2870 lb $0.00** 



# . **Post Bracket -**

# . **Battery**



# . **3 V Pos Terminal Post Bracket - Battery**  **V Pos Terminal 1**  **Stainless Steel $0.00**  **0.1291 lb**



# . **Post Bracket -**



# . **Battery**



# . **4** V Pos Terminal Post Bracket - Battery V Pos Terminal **1** Stainless Steel **$0.00 0.1291 lb** 



# . Post Bracket -



# . Battery



# . **3 V Neg Terminal Post Bracket - Battery**  **V Pos Terminal 1**  **Stainless Steel $0.00**  **0.1291 lb**



# . **Post Bracket -**



# . **Battery**



# . **4** V Neg Terminal Post Bracket - Battery V Pos Terminal **1** Stainless Steel **$0.00 0.1291 lb** 



# . Post Bracket -



# . Battery



# . 3 V Stud - Batt. Cell Terminal V Stud - Batt. 2 Stainless Steel $0.00 0.0109 lb



# . Cell Terminal



# . 3 V Insulator strip - Batt. Terminal V Insulator strip - 1 Plastic $0.00 0.0012 lb



# . Batt. Terminal



# . 3 v Label - Part No. Manuf. v Label - Part 2 Polyethylene $0.00 0.0029 lb



# . No. Manuf.



# . 2 V Screw Terminal Post Bracket - Battery V Screw 4 $0.00 0.0052 lb $0.00



# . Terminal Post



# . Bracket - Battery



# . 1 V Screw - Battery module - tray V Screw - 12 $0.00 0.0033 lb $0.00 V Screw - Battery module - tray V Screw - 0.0033 lb



# . Battery module -



# . tray



# . **1 V Cable-Positive Battery**  **Short V**  **1 Copper**  **$0.00 0.2250 lb**  **$0.00**



# . **Cable-Positive**



# . **Battery 3-6** 



# . **1 V Cable-Positive Battery**  **1-4 V**  **1 Copper**  **$0.00 0.2250 lb**  **$0.00**



# . **Cable-Positive**



# . **Battery 1-4** 



# . **1 V Cable-Positive Battery**  **2-Service Terminal V**  **1 Copper**  **$0.00 0.3850 lb**  **$0.00**



# . **Cable-Positive**



# . **Battery**



# . **2-Service**



# . **Terminal**



# . **1 V Cable-Negative Cable Service Terminal**  **V 1**  **Copper $0.00**  **0.1850 lb $0.00** 



# . **Cable-Negative**



# . **Cable 5-**



# . **Service**



# . **Terminal**



# . 1 V Tie W rap V Tie W rap 

# 2 Nylon 6 

# $0.00 0.0007 lb $0.00

# . Cables



# . 1 V Nut Cable to Battery Terrminal V Nut Cable to 7 $0.00 0.0154 lb $0.00



# . Battery Terrminal



# . 1 V Cover- Battery Terminal Protective V Cover- Battery 4 Rubber $0.00 0.0026 lb $0.00



# . Terminal



# . Protective



# . **1 V Battery**  **Pack Lid V Battery**  **Pack 1**  **Stamped Steel $0.00**  **3.9849 lb $0.00** 



# . **Lid**



# . **2 V Battery**  **Pack Lid V Battery**  **Pack 1**  **Stamped Steel $0.00**  **3.9606 lb $0.00** 



# . **Lid**



# . **3 V Battery**  **Pack Lid V Battery**  **Pack 1**  **Stamped Steel $0.00**  **3.9430 lb**



# . **Lid**



# . **4** V Battery Pack Lid V Battery Pack **1** Stamped Steel **$0.00 3.9430 lb** 



# . Lid



# . 3 v W eld Nut - Projection v W eld Nut - 4 $0.00 0.0028 lb



# . Projection



# . 3 V W eld Nut - Projection Large V W eld Nut - 1 $0.00 0.0064 lb



# . Projection Large



# . 2 V Velcro Patch V Velcro Patch 3 Velcro $0.00 0.0049 lb $0.00



# . 2 V Label - 36V Caution V Label - 36V 1 Polyethylene $0.00 0.0030 lb $0.00



# . Caution



# . 2 V Label - Bar Code V Label - Bar 1 Polyethylene $0.00 0.0031 lb $0.00



# . Code



# . 2 v Label - NiMH Recycle v Label - NiMH 1 Polyethylene $0.00 0.0013 lb $0.00



# . Recycle



# . 2 V Clip - Rosebud W H V Clip - Rosebud 1 Polypropylene $0.00 0.0022 lb $0.00



# . WH



# . 1 V Screw - Battery Pack Lid V Screw - 12 $0.00 0.0038 lb $0.00



# . Battery Pack Lid



# . **1 V Fan - Battery**  **Pack Cooling**

**V Fan - Battery 1**  **$0.00 0.8386 lb**  **$0.00**



# . **Pack Cooling**



# . **2 V Housing - Battery**  **Fan V Housing -**  **1 $0.00**  **0.4413 lb $0.00** 



# . **Battery Fan** 



# . **3 V Housing - Battery**  **Fan V Housing -**  **1 $0.00**  **0.4413 lb**



# . **Battery Fan** 



# . **4** V Housing - Battery Fan V Housing - **1 $0.00**  **0.4413 lb**



# . Battery Fan



# . **2 V Fan A**  **ssy - Batt. Cooling** 

**V Fan A ssy**  **- 1**  **$0.00 0.3664 lb**  **$0.00**



# . **Batt. Cooling**



# . **3 V Housing - Battery**  **Fan Motor V Housing -**  

# 1 **Stamped Steel** 

# $0.00 **0.0509 lb**



# . **Battery Fan** 



# . **Motor**

# . **4** V Housing - Battery Fan Motor V Housing - **1** Stamped Steel **$0.00 0.0509 lb** 



# . Battery Fan



# . Motor



# . 3 V Magnet- Fan Motor V Magnet- Fan 1 Plastic Molded $0.00 0.0481 lb



# . Motor Magnet



# . **3 V Bushing - Brass**  **V Bushing - Fan 1**  **Brass $0.00**  **0.0038 lb**



# . **Motor Shaft**



# . **3 V Shaft- Fan Motor**  **V Shaft- Fan 1**  **Stainless Steel $0.00**  **0.0036 lb**



# . **Motor**



# . **3 V Spring - Fan Motor Shaft**  **V Spring - Fan 1**  **Spring Steel $0.00**  **0.0001 lb**



# . **Motor Shaft**



# . **3 V Bearing - Fan Motor**  **V Bearing - Fan 2**  **Commodity $0.00**  **0.0017 lb**



# . **Motor Pricing** 



# . **3** V Clip Spring - Fan Motor Shaft V Clip Spring - **1** Commodity **$0.00 0.0000 lb** 



# . Fan Motor Shaft Pricing



# . 3 V Blade - Fan V Blade - Fan 1 ABS $0.00 0.0336 lb



# . **3 V Chassis - Batt. Fan**  **V Chassis - 1**  **PBT $0.00**  **0.1310 lb**



# . **Batt. Fan**



# . **4 V Chassis - Batt. Fan**  **V Chassis - 1**  **PBT $0.00**  **0.1310 lb**



# . **Batt. Fan**



# . **5** V Chassis - Batt. Fan V Chassis - Batt. **1** PBT **# 0.1127 lb** 



# . Fan



# . **5 V Shaft - Motor Stator**  **V Shaft - Motor 1**  **Brass #**  **0.0183 lb V Shaft - Motor Stator**  **V Shaft - Motor 0.0183 lb** 



# . **Stator**



# . **6** V Shaft - Motor Stator V Shaft - Motor **1** Brass **# 0.0183 lb** 



# . Stator



# . **3 V PCB - Batt Fan**  **V PCB - Batt 1**  **Commodity $0.00**  **0.0250 lb**



# . **Fan Pricing** 



# . **3 V Stator Windings - Batt. Fan A**  **ssy V Stator**  **1 Commodity**  **$0.00 0.0669 lb** 



# . **Windings - Batt. Prcing** 



# . **Fan A ssy** 



# . **2** V Screw - Batt. Fan to Housing V Screw - Batt. **4 $0.00**  **0.0052 lb $0.00** 



# . Fan to Housing



# . 2 V Label - Bar Code Batt. Fan V Label - Bar 1 Polyethylene $0.00 0.0002 lb $0.00



# . Code Batt. Fan



# . 2 V Label - Batt. Fan W arning V Label - Batt. 1 Polyethylene $0.00 0.0013 lb $0.00



# . Fan W arning



# . 2 V Seal - BAtt. Fan - Case V Seal - BAtt. 2 FOAM $0.00 0.0043 lb $0.00



# . Fan - Case



# . 1 V Screw- Battery Pack Cooling Fan V Screw- Battery 

# 4 $0.00 0.0100 lb $0.00



# . Pack Cooling



# . Fan

# . **1 V Battery**  **Pack Service Door**

**V Battery**

**Pack 1**  **Stamped Steel $0.00**  **1.0100 lb $0.00** 



# . **Service Door**



# . **2 V Battery**  **Pack Service Door**

**V Battery**

**Pack 1**  **Stamped Steel $0.00**  **1.0100 lb $0.00** 



# . **Service Door**



# . **3** V Battery Pack Service Door V Battery Pack **1** Stamped Steel **$0.00 1.0100 lb** 



# . Service Door



# . 1 V Screw Battery Pack Service Door V Screw Battery 1 $0.00 0.0116 lb $0.00



# . Pack Service



# . Door

# TAB LOCATION



# 56.7351 lb

**7.4890 lb** 

# 14 03 75 A 14 03 75

- N0402

- 01 V Tray - Battery

0375A

**4.1936 lb** 

# 14 03 75 A1 14 03 75

- N0402

- 02 V Tray - Battery

0375A

**$0.00 4.1600 lb**  

# 14 03 75 A1 14 03 75

- N0402

- 03 V Tray - Battery

0375A

**$0.00 4.1600 lb** 

$0.00 0.0336 lb 

# 14 03 80 A1 14 03 80

- N0402

- 01 V Tray - Battery

0375A

**0.1210 lb** 

# 14 03 75 A2 14 03 75

- N0402

- 05 V Tray - Battery

0375A

**$0.00 0.1210 lb** 

**0.9024 lb** 

# 14 03 75 A3 14 03 75

- N0402

- 07 V Tray - Battery

0375A

**$0.00 0.7084 lb**  System/Subsytem 

# Part Number

**$0.00 0.7000 lb**  

# 14 03 75 A3 14 03 75

- N0402

- 09 V Tray - Battery

0375A

$0.00 0.0084 lb 

# 14 03 80 A3 14 03 80

- N0402

- 02 V Tray - Battery

0375A

**$0.00 0.1500 lb**  

# 14 03 75 A3 14 03 75

- N0402

- 10 V Tray - Battery

0375A

**$0.00 0.1500 lb** 

**$0.00 0.0348 lb**  

# 14 03 75 A3 14 03 75

- N0402

- 12 V Tray - Battery

0375A

**$0.00 0.0348 lb** 

# $0.00 0.0092 lb 

# 14 03 80 A3 14 03 80

- N0402

- 03 V Tray - Battery

0375A

**0.5116 lb** 

# 14 03 75 A4 14 03 75

- N0402

- 14 V Tray - Battery

0375A

**$0.00 0.4256 lb**  

# 14 03 75 A4 14 03 75

- N0402

- 15 V Tray - Battery

0375A

**$0.00 0.4256 lb** 

**$0.00 0.0420 lb**  

# 14 03 75 A4 14 03 75

- N0402

- 17 V Tray - Battery

0375A

**$0.00 0.0420 lb** 

**$0.00 0.0348 lb**  

# 14 03 75 A4 14 03 75

- N0402

- 19 V Tray - Battery

0375A

**$0.00 0.0348 lb** 

$0.00 0.0092 lb 

# 14 03 80 A4 14 03 80

- N0402

- 04 V Tray - Battery

0375A

**0.2130 lb** 

# 14 03 75 A5 14 03 75

- N0402

- 21 V Tray - Battery

0375A **0.2130 lb** 

# - Battery

**$0.00 0.2130 lb** 



# 0.5116 lb 

# 14 03 75 A6 14 03 75

- N0402

- 23 V Tray - Battery

0375A

**$0.00 0.4256 lb**  

# 14 03 75 A6 14 03 75

- N0402

- 24 V Tray - Battery

0375A

**$0.00 0.4256 lb** 

**$0.00 0.0420 lb**  

# 14 03 75 A6 14 03 75

- N0402

- 26 V Tray - Battery

0375A

**$0.00 0.0420 lb** 

**$0.00 0.0348 lb**  

# 14 03 75 A6 14 03 75

- N0402

- 28 V Tray - Battery

0375A

# $0.00 0.0348 lb

$0.00 0.0092 lb 

# 14 03 80 A6 14 03 80

- N0402

- 05 V Tray - Battery

0375A

**1.0336 lb** 

# 14 03 75 A7 14 03 75

- N0402

- 30 V Tray - Battery

0375A

**$0.00 1.0000 lb**  

# 14 03 75 A7 14 03 75

- N0402

- 31 V Tray - Battery

0375A

**$0.00 1.0000 lb** 

$0.00 0.0336 lb 

# 14 03 80 A7 14 03 80

- N0402

- 06 V Tray - Battery

0375A

**0.0022 lb** 

# 14 03 80 A8 14 03 80

- N0402

- 07 V Tray - Battery

0375A

**1.5714 lb** 

# 14 03 03 A 14 03 03

- N0402

- 01 V Battery Disconnect Unit 0303A

**0.7500 lb** 

# 14 03 03 A1 14 03 03

- N0402

- 02 V Battery Disconnect Unit 0303A **0.7500 lb** 

# V Battery Disconnect Unit 0303A

**$0.00 0.0000 lb**  

# 14 03 03 A1 14 03 03

- N0402

- 03 V Battery Disconnect Unit 0303A

**$0.00 0.0000 lb**  

# 14 03 03 A1 14 03 03

- N0402

- 04 V Battery Disconnect Unit 0303A

**$0.00 0.7500 lb** 

**0.5437 lb** 

# 14 03 03 A2 14 03 03

- N0402

- 06 V Battery Disconnect Unit 0303A

**0.0164 lb** 

# 14 03 80 A3 14 03 80

- N0402

- 08 V Battery Disconnect Unit 0303A

0.0471 lb 

# 14 03 03 A4 14 03 03

- N0402

- 07 V Battery Disconnect Unit 0303A

0.0154 lb 

# 14 03 80 A5 14 03 80

- N0402

- 09 V Battery Disconnect Unit 0303A

0.0000 lb 

# 14 03 03 A6 14 03 03

- N0402

- 08 V Battery Disconnect Unit 0303A

# 0.0207 lb 

# 14 03 03 A7 14 03 03

- N0402

- 09 V Battery Disconnect Unit 0303A

**0.0188 lb** 

# 14 03 80 A8 14 03 80

- N0402

- 10 V Battery Disconnect Unit 0303A

**0.1565 lb** 

# 14 03 03 A9 14 03 03

- N0402

- 10 V Battery Disconnect Unit 0303A

**0.0028 lb** 

# 14 03 80 A10 14 03 80

- N0402

- 11 V Battery Disconnect Unit 0303A

0.0189 lb 

# 14 03 80 A 14 03 80

- N0402

- 12 V Battery Disconnect Unit 0303A

0.0048 lb 

# 14 03 80 B 14 03 80

- N0402

- 13 V Battery Disconnect Unit 0303A

**1.9828 lb** 

# 14 03 03 B 14 03 03

- N0402

- 11 V Harness-Batt. Pack Assy 0303B

**0.8450 lb** 

# 14 03 03 B1 14 03 03

- N0402

- 12 V Harness-Batt. Pack Assy 0303B

**0.4650 lb** 

# 14 03 03 B2 14 03 03

- N0402

- 13 V Harness-Batt. Pack Assy 0303B

**0.4300 lb** 

# 14 03 03 B3 14 03 03

- N0402

- 14 V Harness-Batt. Pack Assy 0303B

**0.2428 lb** 

# 14 03 03 B4 14 03 03

- N0402

- 15 V Harness-Batt. Pack Assy 0303B

**0.0030 lb** 

# 14 03 80 C 14 03 80

- N0402

- 14 V Harness-Batt. Pack Assy 0303B

0.0070 lb 

# 14 03 80 D 14 03 80

- N0402

- 15 V Harness-Batt. Pack Assy 0303B

0.0130 lb 

# 14 03 80 E 14 03 80

- N0402

- 16 V Harness-Batt. Pack Assy 0303B

**38.5353 lb** 

# 14 03 03 C 14 03 03

- N0402

- 16 V Battery Module - NMH 0303C

# 4.9974 lb 

# 14 03 06 C1 14 03 06

- N0402

- 01 V Battery Module - NMH 0303C

**$0.00 4.5960 lb**  

# 14 03 06 C1 14 03 06

- N0402

- 02 V Battery Module - NMH 0303C

**$0.00 4.5960 lb** 

**$0.00 0.4014 lb**  

# 14 03 75 C1 14 03 75

- N0402

- 33 V Battery Module - NMH 0303C

**$0.00 0.4014 lb** 

**30.6000 lb** 

# 14 03 03 C2 14 03 03

- N0402

- 17 V Battery Module - NMH 0303C

**$0.00 0.0000 lb**  

# 14 03 06 C2 14 03 06

- N0402

- 04 V Battery Module - NMH 0303C

**$0.00 0.0000 lb**  

# 14 03 06 C2 14 03 06

- N0402

- 05 V Battery Module - NMH 0303C

**$0.00 0.0000 lb**  

# 14 03 06 C2 14 03 06

- N0402

- 06 V Battery Module - NMH 0303C

**$0.00 0.0000 lb**  

# 14 03 03 C2 14 03 03

- N0402

- 18 V Battery Module - NMH 0303C

**# 0.0000 lb** 

**# 0.0000 lb** 

**$0.00 0.0000 lb**  

# 14 03 06 C2 14 03 06

- N0402

- 07 V Battery Module - NMH 0303C

**1.9800 lb** 

# 14 03 06 C3 14 03 06

- N0402

- 08 V Battery Module - NMH 0303C

**$0.00 1.9800 lb** 

**0.0345 lb** 

# 14 03 03 C4 14 03 03

- N0402

- 21 V Battery Module - NMH 0303C

**0.8610 lb** 

# 14 03 75 C5 14 03 75

- N0402

- 35 V Battery Module - NMH 0303C

# $0.00 **0.3873 lb** 

# 14 03 75 C5 14 03 75

- N0402

- 36 V Battery Module - NMH 0303C

**$0.00 0.3873 lb** 

**$0.00 0.3873 lb**  

# 14 03 75 C5 14 03 75

- N0402

- 38 V Battery Module - NMH 0303C

**$0.00 0.3873 lb** 

$0.00 0.0654 lb 

# 14 03 03 C5 14 03 03

- N0402

- 22 V Battery Module - NMH 0303C

$0.00 0.0036 lb 

# 14 03 03 C5 14 03 03

- N0402

- 23 V Battery Module - NMH 0303C

$0.00 0.0174 lb 

# 14 03 99 C5 14 03 99

- N0402

- 01 V Battery Module - NMH 0303C

0.0624 lb 

# 14 03 80 C6 14 03 80

- N0402

- 17 V Battery Module - NMH 0303C

0.0396 lb 

# 14 03 80 F 14 03 80

- N0402

- 18 V Battery Module - NMH 0303C 0.0396 lb 

# V Battery Module - NMH 0303C

**0.2250 lb** 

# 14 03 03 D 14 03 03

- N0402

- 24 V Battery Module - NMH 0303C

**0.2250 lb** 

# 14 03 03 E 14 03 03

- N0402

- 25 V Battery Module - NMH 0303C

**0.3850 lb** 

# 14 03 03 F 14 03 03

- N0402

- 26 V Battery Module - NMH 0303C

**0.1850 lb** 

# 14 03 03 G 14 03 03

- N0402

- 27 V Battery Module - NMH 0303C

0.0014 lb 

# 14 03 80 G 14 03 80

- N0402

- 19 V Battery Module - NMH 0303C

# 0.1078 lb 

# 14 03 80 H 14 03 80

- N0402

- 20 V Battery Module - NMH 0303C

0.0104 lb 

# 14 03 06 A 14 03 06

- N0402

- 10 V Battery Module - NMH 0303C

**3.9849 lb** 

# 14 03 06 B 14 03 06

- N0402

- 11 V Battery Pack Lid 0306B

**3.9606 lb** 

# 14 03 06 B1 14 03 06

- N0402

- 12 V Battery Pack Lid 0306B

**$0.00 3.9430 lb**  

# 14 03 06 B1 14 03 06

- N0402

- 13 V Battery Pack Lid 0306B

**$0.00 3.9430 lb** 

$0.00 0.0112 lb 

# 14 03 80 B1 14 03 80

- N0402

- 21 V Battery Pack Lid 0306B

$0.00 0.0064 lb 

# 14 03 80 B1 14 03 80

- N0402

- 22 V Battery Pack Lid 0306B

0.0147 lb 

# 14 03 99 B2 14 03 99

- N0402

- 02 V Battery Pack Lid 0306B

0.0030 lb 

# 14 03 99 B3 14 03 99

- N0402

- 03 V Battery Pack Lid 0306B

0.0031 lb 

# 14 03 99 B4 14 03 99

- N0402

- 04 V Battery Pack Lid 0306B

0.0013 lb 

# 14 03 99 B5 14 03 99

- N0402

- 05 V Battery Pack Lid 0306B

0.0022 lb 

# 14 03 80 B6 14 03 80

- N0402

- 23 V Battery Pack Lid 0306B

0.0456 lb 

# 14 03 80 I 14 03 80

- N0402

- 24 V Battery Pack Lid 0306B

**0.8386 lb** 

# 14 03 05 A 14 03 05

- N0402

- 01

**0.4413 lb** 

# 14 03 06 A1 14 03 06

- N0402

- 15

**$0.00 0.4413 lb** 

**$0.00 0.4413 lb** 

**0.3664 lb** 

# 14 03 05 A2 14 03 05

- N0402

- 02

**$0.00 0.0509 lb**  

# 14 03 06 A2 14 03 06

- N0402

- 18

# $0.00 **0.0509 lb**

$0.00 0.0481 lb 

# 14 03 03 A2 14 03 03

- N0402

- 28

**$0.00 0.0038 lb**  

# 14 03 90 A2 14 03 90

- N0402

- 01

**$0.00 0.0036 lb**  

# 14 03 80 A2 14 03 80

- N0402

- 25

**$0.00 0.0001 lb**  

# 14 03 03 A2 14 03 03

- N0402

- 29

**$0.00 0.0034 lb**  

# 14 03 90 A2 14 03 90

- N0402

- 02

**$0.00 0.0000 lb**  

# 14 03 80 A2 14 03 80

- N0402

- 26

$0.00 0.0336 lb 

# 14 03 05 A2 14 03 05

- N0402

- 03

**$0.00 0.1310 lb**  

# 14 03 06 A2 14 03 06

- N0402

- 20

**$0.00 0.1310 lb** 

**# 0.1127 lb** 

**# 0.0183 lb**  

# 14 03 80 A2 14 03 80

- N0402

- 27

**0.0183 lb**

**# 0.0183 lb** 

**$0.00 0.0250 lb**  

# 14 03 03 A2 14 03 03

- N0402

- 30

**$0.00 0.0669 lb**  

# 14 03 03 A2 14 03 03

- N0402

- 31

**0.0208 lb** 

# 14 03 80 A3 14 03 80

- N0402

- 29

0.0002 lb 

# 14 03 99 A4 14 03 99

- N0402

- 06

0.0013 lb 

# 14 03 99 A5 14 03 99

- N0402

- 07

0.0086 lb 

# 14 03 85 A6 14 03 85

- N0402

- 01

0.0400 lb 

# 14 03 80 J 14 03 80

- N0402

- 30

# 1.0100 lb 

# 14 03 06 C 14 03 06

- N0402

- 23

**1.0100 lb**

**$0.00 1.0100 lb** 

0.0116 lb 

# 14 03 80 K 14 03 80

- N0402

- 31

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year):

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV):

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine:

**System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)**  

## Annual Component Volume:

**Component Description: V Battery Module - Nickel Metal Hydride, Traction Battery Assembly**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life:

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB)**

A 

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

1 V Battery Module - NMH 140303-N0402-16 **3** Final assembly of cells / chassis / aluminum separator / terminals T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, MC **432 12**  **3 3**  0.000 **$0.00 $29.83**  **$125.00 $1,125.00**  **$0.00 $0.83**  **$2.60 $3.43**  **0.00% 0.00%** 

1 V Carrier - Battery Module 140306-N0402-01 **3** Weld, Spot - Side Panels and Straps T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Welding/Soldering Operator Mech. Assembly, LC **400 4**  **2 7**  0.000 **$0.00 $41.55**  **$100.00 $1,400.00**  **$0.00 $0.42**  **$3.50 $3.92**  **0.00% 0.00%** 

2 V Chassis Side Panel - Batt. Module 140306-N0402-02 **6** Stamping, Prog. Die - 300 ton T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS **1029 2**  **2 1**  0.889 **$0.45 $42.73**  **$42.91 $85.82**  **$0.40 $0.08**  **$0.08 $0.57**  **0.00% 0.00%** 

3 V Straps- Battery Module Chassis 140375-N0402-33 **18** Stamping, Prog. Die - 25 ton T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **2400 2**  **4 1**  0.047 **$0.45 $42.73**  **$15.50 $62.00**  **$0.02 $0.04**  **$0.03 $0.08**  **0.00% 0.00%** 

4 V Battery - NiMH (Assembled, Charged, & Tested) 140303-N0402-17 **6** Charge / Discharge / Store / Age / Check / Test T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, MC **796 1**  **4 1**  0.000 **$0.00 $29.83**  **$125.00 $500.00**  **$0.00 $0.04**  **$0.63 $0.67**  **0.00% 0.00%** 

5 V Battery - NiMH (Assembled) 140303-N0402-17 **6** Assemble cell case / case terminal / electrodes / foil wrap / labels T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, MC **720 35**  **7 8**  0.000 **$0.00 $29.83**  **$125.00 $7,000.00**  **$0.00 $1.45**  **$9.72 $11.17**  **0.00% 0.00%** 

6 V Battery Cell Case Lid 140306-N0402-05 **6** Injection mold, 4-cavity, 400-ton press T1 Assembly, Mark-up Applied @ Bottom. HD Polypro Mold/Cast/Sinter Operator Inject. Mold, SMS **1440 0.25**  **1 1**  0.111 **$0.87 $41.48**  **$28.80 $28.80**  **$0.10 $0.01**  **$0.02 $0.12**  **0.00% 0.00%** 

7 V Battery Cell Case Outer Walls 140306-N0402-06 **12** Injection mold, 4-cavity, 600-ton press T1 Assembly, Mark-up Applied @ Bottom. HD Polypro Mold/Cast/Sinter Operator Inject. Mold, LS **1371 0.5**  **2 1**  0.171 **$0.87 $41.48**  **$151.77 $303.54**  **$0.15 $0.02**  **$0.22 $0.39**  **0.00% 0.00%** 

8 V Battery Cell Case Terminal Carrier (Assembled) 140303-N0402-18 **6** Assemble molded carrier / contacts / seals / lugs / terminals T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, MC **764 14**  **7 3**  0.000 **$0.00 $29.83**  **$125.00 $2,625.00**  **$0.00 $0.55**  **$3.44 $3.98**  **0.00% 0.00%**  

### 9,574

**10 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Series Gasoline Hybrid**

**MARK-UP COSTS** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Quote Modification Q**  **uote** 

### Differential Quote (Quote S **um mary includes costin**  **g for both T echnology Packages)** 

8 V Battery Cell Case Terminal Carrier (Assembled) 140303-N0402-18 **6** Assemble molded carrier / contacts / seals / lugs / terminals T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, MC **764 14**  **7 3**  0.000 **$0.00 $29.83**  **$125.00 $2,625.00**  **$0.00 $0.55**  **$3.44 $3.98**  **0.00% 0.00%** 

9 V Battery Cell Case Terminal Carrier (Molded) 140303-N0402-18 **6** Injection mold, 4-cavity, 400-ton press T1 Assembly, Mark-up Applied @ Bottom. HD Polypro Mold/Cast/Sinter Operator Inject. Mold, SMS **800 0.25**  **1 1**  0.340 **$0.87 $41.48**  **$28.80 $28.80**  **$0.30 $0.01**  **$0.04 $0.34**  **0.00% 0.00%** 

10 V Post-Cell Terminal Contact 140303-N0402-32 **66** Bar stock cut to length / finish / plate 28.4mm x 5.4mm dia. T1 Assembly, Mark-up Applied @ Bottom. HC-Steel-1040S, Bar CNC Operator CNC Machining, LC **8400 3.5**  **7 1**  0.016 **$0.80 $36.98**  **$30.38 $212.66**  **$0.01 $0.02**  **$0.03 $0.05**  **0.00% 0.00%** 

11 V Post Plate - Terminal Lug Bar Stock 140303-N0402-33 **12** EC-300 - Pallet Size 300 mm square, 550 lb Capacity T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Bar CNC Operator CNC Machining, LC **1414 5.5**  **11 1**  0.018 **$1.65 $36.98**  **$30.38 $334.18**  **$0.03 $0.14**  **$0.24 $0.41**  **0.00% 0.00%** 

12 V Lug Post - Terminal Bar Stock 140303-N0402-34 **12** EC-300 - Pallet Size 300 mm square, 550 lb Capacity T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Bar CNC Operator CNC Machining, LC **1277 5.5**  **11 1**  0.053 **$1.65 $36.98**  **$30.38 $334.18**  **$0.09 $0.16**  **$0.26 $0.51**  **0.00% 0.00%** 

13 V Battery Cell Case Floor 140306-N0402-07 **6** Injection molded 289.54mm x 45.8mm x 3.5mm T1 Assembly, Mark-up Applied @ Bottom. HD Polypro Mold/Cast/Sinter Operator Inject. Mold, SMS **1108 0.25**  **1 1**  0.161 **$0.87 $41.48**  **$28.80 $28.80**  **$0.14 $0.01**  **$0.03 $0.18**  **0.00% 0.00%** 

14 V Seal Piston - Battery Vent 140303-N0402-42 **6** Snap together piston and seal T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Work Cell Assembly Mech Assembly, LC, Base **720 1**  **1 1**  0.000 **$0.00 $39.23**  **$15.00 $15.00**  **$0.00 $0.05**  **$0.02 $0.08**  **0.00% 0.00%** 

15 V Piston - Vent Seal 140303-N0402-43 **6** Injection mold, 10-cavity, 5-ton press T1 Assembly, Mark-up Applied @ Bottom. HD Polypro Mold/Cast/Sinter Operator Inject. Mold, SS **4000 0.5**  **1 1**  0.001 **$0.87 $41.48**  **$16.39 $16.39**  **$0.00 $0.01**  **$0.00 $0.01**  **0.00% 0.00%** 

16 V Seal - Battery Vent 140385-N0402-02 **6** Injection mold, 10-cavity, 4-ton press T1 Assembly, Mark-up Applied @ Bottom. Thermoset-AU Mold/Cast/Sinter Operator Inject. Mold, SS **4000 0.5**  **1 1**  0.001 **$1.77 $41.48**  **$16.39 $16.39**  **$0.00 $0.01**  **$0.00 $0.01**  **0.00% 0.00%** 

17 V Cap - Battery Vent 140306-N0402-24 **6** Injection mold, 10-cavity, 10-ton press T1 Assembly, Mark-up Applied @ Bottom. HD Polypro Mold/Cast/Sinter Operator Inject. Mold, SS **9000 0.5**  **1 1**  0.003 **$0.87 $41.48**  **$16.39 $16.39**  **$0.00 $0.00**  **$0.00 $0.01**  **0.00% 0.00%** 

18 Electrolyte - Potasium Hydroxide - Dry Room & Heat 140303-N0402-44 **0** Dry Room & Heat T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, HC, Base **787 1**  **2 2**  0.000 **$0.00 $29.83**  **$75.00 $300.00**  **$0.00 $0.04**  **$0.38 $0.42**  **0.00% 0.00%** 

19 Electrolyte - Potasium Hydroxide - Vac Fill, Weld, and Seal 140303-N0402-44 **0** Fill / Heat Weld / Seal T1 Assembly, Mark-up Applied @ Bottom. aqueous solution of potassium hydroxide Welding/Soldering Operator Elec. Assembly, HC, Base **720 4**  **4 1**  0.214 **$9.61 $41.55**  **$75.00 $300.00**  **$2.06 $0.23**  **$0.42 $2.70**  **0.00% 0.00%** 

20 V Separator - Battery Chassis 140306-N0402-08 **6** Aluminum Extrusion T1 Assembly, Mark-up Applied @ Bottom. Aluminum-2024, Bar Extruding/Drawing Operator Cold Forge, LMC **450 1**  **1 1**  0.162 **$2.38 $56.05**  **$100.00 $100.00**  **$0.39 $0.12**  **$0.22 $0.73**  **0.00% 0.00%** 

21 VTerminal Post Bracket - Battery 140375-N0402-35 **3** Apply insulator strip & label / Bake / Cure T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, LC **351 1**  **1 1**  0.000 **$0.00 $29.83**  **$100.00 $100.00**  **$0.00 $0.08**  **$0.28 $0.37**  **0.00% 0.00%** 

22 VTerminal Post Bracket - Battery 140375-N0402-35 **3** Press studs to terminal posts T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, LC **138 1**  **1 1**  0.000 **$0.00 $29.83**  **$100.00 $100.00**  **$0.00 $0.22**  **$0.72 $0.94**  **0.00% 0.00%** 

23 V Pos Terminal Post Bracket - Battery 140375-N0402-36 **3** Stamping, Prog. Die - 6 ton T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Bar Cut/Punch/Forming Operator Stamp/Form, Terminals **360 0.5**  **1 1**  0.344 **$1.65 $42.73**  **$15.50 $15.50**  **$0.57 $0.06**  **$0.04 $0.67**  **0.00% 0.00%** 

24 V Neg Terminal Post Bracket - Battery 140375-N0402-38 **3** Stamping, Prog. Die - 6 ton T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Bar Cut/Punch/Forming Operator Stamp/Form, Terminals **360 0.5**  **1 1**  0.344 **$1.65 $42.73**  **$15.50 $15.50**  **$0.57 $0.06**  **$0.04 $0.67**  **0.00% 0.00%** 



### D 

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

1 V Sensor - Battery Temp 140303-N0402-21 **3** S

2 v Label - Part No. Manuf. 140399-N0402-01 **6** S Polyethylene

3 V Screw Terminal Post Bracket - Battery 140380-N0402-17 **12** S

4 V Screw - Battery module - tray 140380-N0402-18 **12** S

5 V Tie Wrap 140380-N0402-19 **2** S

6 V Nut Cable to Battery Terrminal 140380-N0402-20 **7** S

7 V Stud - Batt. Cell Terminal 140303-N0402-22 **6** S Stainless Steel 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

- Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final

or Sub

- Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus

component cost will only be included for Mark

- up Calculations.

"Alpha

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

Subassembly. Pulled into Electrode Subassembly Worksheet

8 V Seals - Seals Terminal Posts 140385-N0402-03 **12** S

9 V Spring - Battery Vent 140399-N0402-12 **6** S

10 V Label - Battery Cell Bar Code 140399-N0402-13 **6** S

11 V Insulator strip - Batt. Terminal 140303-N0402-23 **3** S

12 V Cable-Positive Battery Short 140303-N0402-24 **1** 1.2 ft (10mm Dia) S

13 V Cable-Positive Battery 1-4 140303-N0402-25 **1** 1.2 ft (10mm Dia) S

14 V Cable-Positive Battery 2-Service Terminal 140303-N0402-26 **1** 2.1 ft (10mm Dia) S

15 V Cable-Negative Cable Service Terminal 140303-N0402-27 **1** 0.84 ft (10mm Dia) S

16 V Cover- Battery Terminal Protective 140306-N0402-10 **4** Formed rubber S

17 V Foil Applique - Battery Sides 140399-N0402-08 **12** 2.5" x 11 1/4" each = 28.125 sq " ($0.00017/sq " = $0.005/pc) S

18 v Foil Applique - Battery Bottom 140399-N0402-09 **6** 1.375" x 10 1/4" each = 14.094 sq " ($0.00017/sq " = $0.0024/pc) S 

### Subassembly.



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year):

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV):

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine:

**System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)**  

## Annual Component Volume:

**Component Description: V Battery Module - Nickel Metal Hydride, Traction Battery Assembly**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life:

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) 9,574** 

**10 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Series Gasoline Hybrid**

**MARK-UP COSTS** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Quote Modification Q**  **uote** 

### Differential Quote (Quote S **um mary includes costin**  **g for both T echnology Packages)** 

19 V Foil Applique - Battery Top 140399-N0402-10 **6** 1.375" x 10 1/4" each = 14.094 sq " ($0.00017/sq " = $0.0024/pc) S

**Material Labor**  **Burden TMC**  **Scrap SG&A** 

**T1 or OEM Total Manufacturing Cost: $41.95**  **$24.50 $117.60**  **$184.04 $0.00**  **$0.00**

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

----- ----- ----- ----- 0.70% 7.00%

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

----- ----- ----- **$1.29 $12.88** 

**Base Cost Impact to Vehicle: $41.95**  **$24.50 $117.60**  **$184.04 $1.29**  **$12.88**

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment (%) Total # of** 

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d**



### Rack/Pallet Investment Amortization: **$1.077 $2,154,300**  **0.00% 2,250,000**  **60 5.00%**  $150 **14362**

**Packaging**

**Cost per**

**Piece Tier Pad Price** 

**Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1 Pads** 

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack**



### Expendable Packaging in Piece Cost: **$1.25** $0.00 0 $0.00 0 $0.00 0 $5.00 1



### Packaging Cost Total: **$2.327** 

### PACKAGING CALCULATIONS:

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers: **Reference Packaging Database for Additonal Infromation**

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

V Battery Module - NMH 140303-N0402-16

V Carrier - Battery Module 140306-N0402-01

V Chassis Side Panel - Batt. Module 140306-N0402-02

V Straps- Battery Module Chassis 140375-N0402-33

V Battery - NiMH (Assembled, Charged, & Tested) 140303-N0402-17

V Battery - NiMH (Assembled) 140303-N0402-17

V Battery Cell Case Lid 140306-N0402-05

V Battery Cell Case Outer Walls 140306-N0402-06

V Battery Cell Case Terminal Carrier (Assembled) 140303-N0402-18



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc. 

## OEM Plant Location:

Supplier Plant Location:

OEM/T1 Classification: **T1 High Assembly Complexity**



## Shipping Method:

Packaging Specification: **Stackable Totes (Flexcon)**



## Production Year: **2008/2009**

**Profit**

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark-up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr.**

**0.00% 0.00%**  **0.00% $0.00**  **$3.43 $10.30**  **$0.00 $2.49**  **$7.81 $10.30**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 4**  **2 10**  **80 47**  **3760**

**0.00% 0.00%**  **0.00% $0.00**  **$3.92 $11.75**  **$0.00 $1.25**  **$10.50 $11.75**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** We ld, Spot - Side Panels and Straps **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.57 $3.40**  **$2.40 $0.50**  **$0.50 $3.40**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Stamping, Prog. Die - 300 ton **3.5 2**  **10 70**  **47 3290** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.08 $1.49**  **$0.38 $0.64**  **$0.47 $1.49**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Stamping, Prog. Die - 25 ton **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.67 $3.99**  **$0.00 $0.22**  **$3.77 $3.99**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Charge / Discharge / Store / Age / Check / Test **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$11.17 $67.03**  **$0.00 $8.70**  **$58.33 $67.03**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Assemble cell case / case terminal / electrodes / foil wrap / labels **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.12 $0.74**  **$0.58 $0.04**  **$0.12 $0.74**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Inj ection mold, 4-cavity, 400-ton press **2.5 2**  **10 50**  **47 2350** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.39 $4.62**  **$1.79 $0.18**  **$2.66 $4.62**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Inj ection mold, 4-cavity, 600-ton press **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$3.98 $23.91**  **$0.00 $3.28**  **$20.63 $23.91**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Assemble molded carrier / contacts / seals / lugs / terminals **4.5 2**  **10 90**  **47 4230**  

### North America

**North America**

**FOB Ship Point**

**Projected Operating Pattern MARK-UP COSTS**  **MANUFACTURING ASSUMPTIONS**

**Manufacturing Costs x Quantity Process Information**  **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**TOTAL COSTS TOOLING & INVESTMENT** 

V Battery Cell Case Terminal Carrier (Assembled) 140303-N0402-18

V Battery Cell Case Terminal Carrier (Molded) 140303-N0402-18

V Post-Cell Terminal Contact 140303-N0402-32

V Post Plate - Terminal Lug Bar Stock 140303-N0402-33

V Lug Post - Terminal Bar Stock 140303-N0402-34

V Battery Cell Case Floor 140306-N0402-07

V Seal Piston - Battery Vent 140303-N0402-42

V Piston - Vent Seal 140303-N0402-43

V Seal - Battery Vent 140385-N0402-02

V Cap - Battery Vent 140306-N0402-24

Electrolyte - Potasium Hydroxide - Dry Room & Heat 140303-N0402-44

Electrolyte - Potasium Hydroxide - Vac Fill, Weld, and Seal 140303-N0402-44

V Separator - Battery Chassis 140306-N0402-08

VTerminal Post Bracket - Battery 140375-N0402-35

VTerminal Post Bracket - Battery 140375-N0402-35

V Pos Terminal Post Bracket - Battery 140375-N0402-36

V Neg Terminal Post Bracket - Battery 140375-N0402-38



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

V Sensor - Battery Temp 140303-N0402-21

v Label - Part No. Manuf. 140399-N0402-01

V Screw Terminal Post Bracket - Battery 140380-N0402-17

V Screw - Battery module - tray 140380-N0402-18

V Tie Wrap 140380-N0402-19

V Nut Cable to Battery Terrminal 140380-N0402-20

V Stud - Batt. Cell Terminal 140303-N0402-22 **0.00% 0.00%**  **0.00% $0.00**  **$3.98 $23.91**  **$0.00 $3.28**  **$20.63 $23.91**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Assemble molded carrier / contacts / seals / lugs / terminals **4.5 2**  **10 90**  **47 4230** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.34 $2.07**  **$1.77 $0.08**  **$0.22 $2.07**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Inj ection mold, 4-cavity, 400-ton press **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.05 $3.53**  **$0.84 $1.02**  **$1.67 $3.53**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Bar stock cut to length / finish / plate 28.4mm x 5.4mm dia. **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.41 $4.91**  **$0.35 $1.73**  **$2.84 $4.91**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** EC-300 - Pallet Size 300 mm square, 550 lb Capacity **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.51 $6.10**  **$1.05 $1.91**  **$3.14 $6.10**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** EC-300 - Pallet Size 300 mm square, 550 lb Capacity **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.18 $1.05**  **$0.84 $0.06**  **$0.16 $1.05**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Inj ection molded 289.54mm x 45.8mm x 3.5mm **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.08 $0.45**  **$0.00 $0.33**  **$0.13 $0.45**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Snap together piston and seal **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.01 $0.06**  **$0.01 $0.03**  **$0.02 $0.06**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Inj ection mold, 10-cavity, 5-ton press **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.01 $0.07**  **$0.01 $0.03**  **$0.02 $0.07**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Inj ection mold, 10-cavity, 4-ton press **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.01 $0.04**  **$0.02 $0.01**  **$0.01 $0.04**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Inj ection mold, 10-cavity, 10-ton press **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.42 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Dry Room & Heat **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$2.70 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Fill / Heat W eld / Seal **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.73 $4.40**  **$2.32 $0.75**  **$1.33 $4.40**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Aluminum Extrusion **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.37 $1.11**  **$0.00 $0.25**  **$0.85 $1.11**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Apply insulator strip & label / Bake / Cure **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.94 $2.81**  **$0.00 $0.65**  **$2.17 $2.81**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Press studs to terminal posts **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.67 $2.01**  **$1.70 $0.18**  **$0.13 $2.01**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Stamping, Prog. Die - 6 ton **5 2**  **10 100**  **47 4700** 

**0.00% 0.00%**  **0.00% $0.00**  **$0.67 $2.01**  **$1.70 $0.18**  **$0.13 $2.01**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Stamping, Prog. Die - 6 ton **5 2**  **10 100**  **47 4700** 

**Supplier**

**Account**

**Cost Purchase** 

**Price/ Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

**$0.00** $4.00 **$0.00 $12.00**  **$12.00 $12.00** 

**$0.00** $0.05 **$0.00 $0.30**  **$0.30 $0.30** 

**$0.00** $0.03 **$0.00 $0.36**  **$0.36 $0.36** 

**$0.00** $0.03 **$0.00 $0.36**  **$0.36 $0.36** 

**$0.00** $0.02 **$0.00 $0.04**  **$0.04 $0.04** 

**$0.00** $0.03 **$0.00 $0.21**  **$0.21 $0.21** 

**$0.00** $0.30 **$0.00 $1.80**  **$1.80 $1.80** 

V Seals - Seals Terminal Posts 140385-N0402-03

V Spring - Battery Vent 140399-N0402-12

V Label - Battery Cell Bar Code 140399-N0402-13

V Insulator strip - Batt. Terminal 140303-N0402-23

V Cable-Positive Battery Short 140303-N0402-24

V Cable-Positive Battery 1-4 140303-N0402-25

V Cable-Positive Battery 2-Service Terminal 140303-N0402-26

V Cable-Negative Cable Service Terminal 140303-N0402-27

V Cover- Battery Terminal Protective 140306-N0402-10

V Foil Applique - Battery Sides 140399-N0402-08

v Foil Applique - Battery Bottom 140399-N0402-09 **$0.00** $0.04 **$0.00 $0.48**  **$0.48 $0.48** 

**$0.00** $0.04 **$0.00 $0.24**  **$0.24 $0.24** 

**$0.00** $0.05 **$0.00 $0.30**  **$0.30 $0.30** 

**$0.00** $0.06 **$0.00 $0.18**  **$0.18 $0.18** 

**$0.00** $2.25 **$0.00 $2.25**  **$2.25 $2.25** 

**$0.00** $2.25 **$0.00 $2.25**  **$2.25 $2.25** 

**$0.00** $3.25 **$0.00 $3.25**  **$3.25 $3.25** 

**$0.00** $1.84 **$0.00 $1.84**  **$1.84 $1.84** 

**$0.00** $0.06 **$0.00 $0.24**  **$0.24 $0.24** 

**$0.00** $0.005 **$0.00 $0.06**  **$0.06 $0.06** 

**$0.00** $0.003 **$0.00 $0.02**  **$0.02 $0.02** 



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

V Foil Applique - Battery Top 140399-N0402-10 

## OEM Plant Location:

Supplier Plant Location:

OEM/T1 Classification: **T1 High Assembly Complexity**



## Shipping Method:

Packaging Specification: **Stackable Totes (Flexcon)**



## Production Year: **2008/2009**

**Profit**

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark-up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. North America** 

**North America**

**FOB Ship Point**

**Projected Operating Pattern MARK-UP COSTS**  **MANUFACTURING ASSUMPTIONS**

**Manufacturing Costs x Quantity Process Information**  **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**TOTAL COSTS TOOLING & INVESTMENT** 

**$0.00** $0.003 **$0.00 $0.02**  **$0.02 $0.02** 

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

**Total**

**$41.95 $24.50**  **$117.60 $184.04**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**Profit ED&T**  **Total**

**Mark-up $184.04**  **$184.04**

**$0.00 $0.00**  **$0.00 $184.04** 

8.00% 4.00% 19.70%

**$14.72 $7.36**  **$36.26**

**$14.72 $7.36**  **$36.26 $220.30**  **$0 $0**  **3 1**  **2**



### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**

**Packaging Cost: $2.33** 

**Net Cost Impact to Vehicle: $222.63** **N u** **m b** **e r** **o f** **P a** **r t** **s p** **e r** **P a** **l l** **e t** **/ R** **a c** **k S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**

4 **6 57447** 

**Other #3**

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**

$0.00 0



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

V Battery Module - NMH 140303-N0402-16

V Carrier - Battery Module 140306-N0402-01

V Chassis Side Panel - Batt. Module 140306-N0402-02

V Straps- Battery Module Chassis 140375-N0402-33

V Battery - NiMH (Assembled, Charged, & Tested) 140303-N0402-17

V Battery - NiMH (Assembled) 140303-N0402-17

V Battery Cell Case Lid 140306-N0402-05

V Battery Cell Case Outer Walls 140306-N0402-06

V Battery Cell Case Terminal Carrier (Assembled) 140303-N0402-18



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**

**359 10.03**  **85% 422**  **8.52** 105 5 1 25 **3.0 3.0**  **432 8.33**  12.00

**287 12.53**  **85% 338**  **10.65** 111 7 1 18 **7.0 2.0**  **400 9.00**  4.00

**821 4.39**  **85% 965**  **3.73** 7 1 1 7 **1.0 2.0**  **1029 3.50**  2.00

**1723 2.09**  **85% 2028**  **1.78** 6 1 1 6 **1.0 4.0**  **2400 1.50**  2.00

**574 6.27**  **85% 676**  **5.33** 7,235 1 400 7,235 **1.0 4.0**  **796 4.52**  1.00

**574 6.27**  **85% 676**  **5.33** 249 8 1 35 **8.0 7.0**  **720 5.00**  35.00

**1149 3.13**  **85% 1352**  **2.66** 10 1 4 10 **1.0 1.0**  **1440 2.50**  0.25

**1149 3.13**  **85% 1352**  **2.66** 21 1 4 21 **1.0 2.0**  **1371 2.63**  0.50

**638 5.64**  **85% 751**  **4.79** 97 3 1 33 **3.0 7.0**  **764 4.71**  14.00 

### Minimum Calculated Cycles Time **MANUFACTURING ASSUMPTIONS**

**Project Process Requirement**

V Battery Cell Case Terminal Carrier (Assembled) 140303-N0402-18

V Battery Cell Case Terminal Carrier (Molded) 140303-N0402-18

V Post-Cell Terminal Contact 140303-N0402-32

V Post Plate - Terminal Lug Bar Stock 140303-N0402-33

V Lug Post - Terminal Bar Stock 140303-N0402-34

V Battery Cell Case Floor 140306-N0402-07

V Seal Piston - Battery Vent 140303-N0402-42

V Piston - Vent Seal 140303-N0402-43

V Seal - Battery Vent 140385-N0402-02

V Cap - Battery Vent 140306-N0402-24

Electrolyte - Potasium Hydroxide - Dry Room & Heat 140303-N0402-44

Electrolyte - Potasium Hydroxide - Vac Fill, Weld, and Seal 140303-N0402-44

V Separator - Battery Chassis 140306-N0402-08

VTerminal Post Bracket - Battery 140375-N0402-35

VTerminal Post Bracket - Battery 140375-N0402-35

V Pos Terminal Post Bracket - Battery 140375-N0402-36

V Neg Terminal Post Bracket - Battery 140375-N0402-38



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

V Sensor - Battery Temp 140303-N0402-21

v Label - Part No. Manuf. 140399-N0402-01

V Screw Terminal Post Bracket - Battery 140380-N0402-17

V Screw - Battery module - tray 140380-N0402-18

V Tie Wrap 140380-N0402-19

V Nut Cable to Battery Terrminal 140380-N0402-20

V Stud - Batt. Cell Terminal 140303-N0402-22 **638 5.64**  **85% 751**  **4.79** 97 3 1 33 **3.0 7.0**  **764 4.71**  14.00

**574 6.27**  **85% 676**  **5.33** 18 1 4 18 **1.0 1.0**  **800 4.50**  0.25

**6319 0.57**  **85% 7434**  **0.48** 3 1 1 3 **1.0 7.0**  **8400 0.43**  3.50

**1149 3.13**  **85% 1352**  **2.66** 28 1 1 28 **1.0 11.0**  **1414 2.55**  5.50

**1149 3.13**  **85% 1352**  **2.66** 31 1 1 31 **1.0 11.0**  **1277 2.82**  5.50

**574 6.27**  **85% 676**  **5.33** 13 1 4 13 **1.0 1.0**  **1108 3.25**  0.25

**574 6.27**  **85% 676**  **5.33** 7 1 1 5 **1.0 1.0**  **720 5.00**  1.00

**574 6.27**  **85% 676**  **5.33** 9 1 10 9 **1.0 1.0**  **4000 0.90**  0.50

**574 6.27**  **85% 676**  **5.33** 9 1 10 9 **1.0 1.0**  **4000 0.90**  0.50

**574 6.27**  **85% 676**  **5.33** 4 1 10 4 **1.0 1.0**  **9000 0.40**  0.50

**0 #DIV/0!**  **85% 0**  **#DIV/0!** 3,660 2 400 3,660 **2.0 2.0**  **787 4.58**  1.00

**0 #DIV/0!**  **85% 0**  **#DIV/0!** 38 1 1 20 **1.0 4.0**  **720 5.00**  4.00

**574 6.27**  **85% 676**  **5.33** 8 1 1 8 **1.0 1.0**  **450 8.00**  1.00

**287 12.53**  **85% 338**  **10.65** 410 1 40 410 **1.0 1.0**  **351 10.25**  1.00

**287 12.53**  **85% 338**  **10.65** 26 1 1 26 **1.0 1.0**  **138 26.00**  1.00

**287 12.53**  **85% 338**  **10.65** 10 1 1 10 **1.0 1.0**  **360 10.00**  0.50

**287 12.53**  **85% 338**  **10.65** 10 1 1 10 **1.0 1.0**  **360 10.00**  0.50

V Seals - Seals Terminal Posts 140385-N0402-03

V Spring - Battery Vent 140399-N0402-12

V Label - Battery Cell Bar Code 140399-N0402-13

V Insulator strip - Batt. Terminal 140303-N0402-23

V Cable-Positive Battery Short 140303-N0402-24

V Cable-Positive Battery 1-4 140303-N0402-25

V Cable-Positive Battery 2-Service Terminal 140303-N0402-26

V Cable-Negative Cable Service Terminal 140303-N0402-27

V Cover- Battery Terminal Protective 140306-N0402-10

V Foil Applique - Battery Sides 140399-N0402-08

v Foil Applique - Battery Bottom 140399-N0402-09



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

V Foil Applique - Battery Top 140399-N0402-10**P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Minimum Calculated Cycles Time **MANUFACTURING ASSUMPTIONS**

**Project Process Requirement**

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 1 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 High Assembly Complexity**



## System Description: **Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)** 

## Annual Component Volume: Shipping Method:

**Component Description: Part Number:**  **140301-N0402-01-999** 

## We ekly Component Volume: Packaging Specification: **N/A Considered WIP (work in progress)**



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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

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

1 1A Main Cell Assembly 140301-N0402-01-875 **60** Final Assembly of D-Cell T1 Assembly, Mark-up Applied

@ Bottom. Not Applicable General Assembly D-Cell, NiMH, Main Assembly **7200 10**  **2 1**  0.000 **$0.00 $38.55**  **$534.64 $1,069.28**  **$0.00 $0.05**  **$0.15 $0.20**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.20 $12.12**  **$0.00**

2 4A Formation Process 140301-N0402-01-876 **60** Charge/Discharge Cycling T1 Assembly, Mark-up Applied

@ Bottom. Not Applicable General Assembly D-Cell, NiMH, Formation **7200 6**  **2 1**  0.000 **$0.00 $38.55**  **$996.57 $1,993.14**  **$0.00 $0.03**  **$0.28 $0.31**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.31 $18.54**  **$0.00**

3 5A Thermal Cycle & Functional Test 140301-N0402-01-877 **60** Thermal Soak, Cycle,

Functional Test T1 Assembly, Mark-up Applied

@ Bottom. Not Applicable General Assembly D-Cell, NiMH, Thermal Soak &

Test **7200 6**  **2 1**  0.000 **$0.00 $38.55**  **$78.76 $157.52**  **$0.00 $0.03**  **$0.02 $0.05**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.05 $3.24**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### 450,000

**V Battery Module - Nickel Metal Hydride, Traction Battery Assembly (3 battery modules, 2 sub-modules per modules, 10**

**cells per sub-module, total of 60 cells)** 

### 9,574

**10**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **North America**

**North America**

**FOB Ship Point 47** 

**450,000**

**1 Mild Series Gasoline Hybrid** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping)

T1 Assembly, Mark-up Applied D-Cell, NiMH, Pos. Electrode 1 1A Cathode Electrode Material Preparation 140301-N0402-01-850 **60** Material preparation, mixing T1 Assembly, Mark-up Applied

@ Bottom. Not Applicable General Assembly D-Cell, NiMH, Pos. Electrode

Mat. Prep. **7200 4**  **2 1**  0.000 **$0.00 $38.55**  **$48.98 $97.96**  **$0.00 $0.02**  **$0.01 $0.04**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.04 $2.10**  **$0.00**

2 1B Cathode Electrode Coating 140301-N0402-01-851 **60** Coat, Cure, Slit T1 Assembly, Mark-up Applied

@ Bottom. Not Applicable General Assembly D-Cell, NiMH, Pos. Electrode

Coating **7200 4**  **2 1**  0.000 **$0.00 $38.55**  **$179.54 $359.08**  **$0.00 $0.02**  **$0.05 $0.07**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.07 $4.28**  **$0.00**

3 1C Cathode Electrode Compaction 140301-N0402-01-852 **60** Compaction, weld current

collector strip, cut to length. T1 Assembly, Mark-up Applied

@ Bottom. Not Applicable General Assembly D-Cell, NiMH, Pos. Electrode

Compaction **7200 4**  **2 1**  0.000 **$0.00 $38.55**  **$59.90 $119.80**  **$0.00 $0.02**  **$0.02 $0.04**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.04 $2.28**  $0.144 $8.66 **$0.00**

4 2A Anode Electrode Material Preparation 140301-N0402-01-853 **60** Material preparation, mixing T1 Assembly, Mark-up Applied

@ Bottom. Not Applicable General Assembly D-Cell, NiMH, Neg. Electrode

Mat. Prep. **7200 4**  **2 1**  0.000 **$0.00 $38.55**  **$68.53 $137.06**  **$0.00 $0.02**  **$0.02 $0.04**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.04 $2.43**  **$0.00**

5 2B Anode Electrode Coating 140301-N0402-01-854 **60** Coat, Cure, Slit T1 Assembly, Mark-up Applied

@ Bottom. Not Applicable General Assembly D-Cell, NiMH, Neg. Electrode

Coating **7200 4**  **2 1**  0.000 **$0.00 $38.55**  **$173.13 $346.26**  **$0.00 $0.02**  **$0.05 $0.07**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.07 $4.17**  **$0.00**

6 2C Anode Electrode Compaction 140301-N0402-01-855 **60** Compaction, cut to length. T1 Assembly, Mark-up Applied

@ Bottom. Not Applicable General Assembly D-Cell, NiMH, Neg. Electrode

Compaction **7200 4**  **2 1**  0.000 **$0.00 $38.55**  **$49.32 $98.64**  **$0.00 $0.02**  **$0.01 $0.04**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.04 $2.11**  $0.145 $8.704 **$0.00**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 2 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 High Assembly Complexity**



## System Description: **Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)** 

## Annual Component Volume: Shipping Method:

**Component Description: Part Number:**  **140301-N0402-01-999** 

## We ekly Component Volume: Packaging Specification: **N/A Considered WIP (work in progress)**



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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **450,000**

**V Battery Module - Nickel Metal Hydride, Traction Battery Assembly (3 battery modules, 2 sub-modules per modules, 10**

**cells per sub-module, total of 60 cells)** 

### 9,574

**10**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **North America**

**North America**

**FOB Ship Point 47** 

**450,000**

**1 Mild Series Gasoline Hybrid** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

8 **0 #####**  **0 2**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### C 

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

1 1A Positive Electrode Purchased in Raw Material,

PAS (Binder) 140301-N0402-01-800 **60** Not Applicable T1 Assembly, Mark-up Applied

@ Bottom. D-Cell, NiMH, PAS (Binder) Not Applicable Not Applicable **3600 0**  **1 1**  0.00020 **$2.33 $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 $0.03**  **$0.03**

2 1B Positive Electrode Purchased in Raw Material,

Positive Substrate 140301-N0402-01-801 **60** Not Applicable T1 Assembly, Mark-up Applied

@ Bottom. D-Cell, NiMH, Positive

Substrate Not Applicable Not Applicable **3600 0**  **1 1**  0.02226 **$25.00 $0.00**  **$0.00 $0.00**  **$0.56 $0.00**  **$0.00 $0.56**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.56 $33.39**  **$33.39**

3 1C Positive Electrode Purchased in Raw Material,

Nickel Strip 140301-N0402-01-802 **60** Not Applicable T1 Assembly, Mark-up Applied

@ Bottom. D-Cell, NiMH, Nickel Strip Not Applicable Not Applicable **3600 0**  **1 1**  0.00371 **$26.76 $0.00**  **$0.00 $0.00**  **$0.10 $0.00**  **$0.00 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $5.95**  **$5.95**

4 1D Positive Electrode Purchased in Raw Material,

Positive Powder 140301-N0402-01-803 **60** Not Applicable T1 Assembly, Mark-up Applied

@ Bottom. D-Cell, NiMH, Positive Powder Not Applicable Not Applicable **3600 0**  **1 1**  0.06197 **$12.73 $0.00**  **$0.00 $0.00**  **$0.79 $0.00**  **$0.00 $0.79**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.79 $47.33**  **$47.33**

5 1E Positive Electrode Purchased in Raw Material,

Cobalt Powder 140301-N0402-01-804 **60** Not Applicable T1 Assembly, Mark-up Applied

@ Bottom. D-Cell, NiMH, Cobalt Powder Not Applicable Not Applicable **3600 0**  **1 1**  0.00397 **$27.50 $0.00**  **$0.00 $0.00**  **$0.11 $0.00**  **$0.00 $0.11**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.11 $6.55**  **$6.55**

6 1F Positive Electrode Purchased in Raw Material,

Cobalt Oxide 140301-N0402-01-805 **60** Not Applicable T1 Assembly, Mark-up Applied

@ Bottom. D-Cell, NiMH, Cobalt Oxide Not Applicable Not Applicable **3600 0**  **1 1**  0.00421 **$31.82 $0.00**  **$0.00 $0.00**  **$0.13 $0.00**  **$0.00 $0.13**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.13 $8.04**  1.69 $ 101.28

$ **$8.04**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

Negative Electrode Purchased in Raw Material, 

### Section Modified to Capture Raw Material Costs for Postive and Negative Electrodes

8 2A Carboxyl Methyl Cellulose (Thickener) 140301-N0402-01-810 **60** Not Applicable T1 Assembly, Mark-up Applied

@ Bottom. D-Cell, NiMH, Carboxyl Methyl

Cellulose (Thickener) Not Applicable Not Applicable **3600 0**  **1 1**  0.00062 **$7.00 $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 $0.26**  **$0.26**

9 2B Negative Electrode Purchased in Raw Material,

PTFE Binder 140301-N0402-01-811 **60** Not Applicable T1 Assembly, Mark-up Applied

@ Bottom. D-Cell, NiMH, PTFE (Binder) Not Applicable Not Applicable **3600 0**  **1 1**  0.00171 **$7.20 $0.00**  **$0.00 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.01 $0.74**  **$0.74**

10 2C Negative Electrode Purchased in Raw Material,

Nickel Substrate 140301-N0402-01-812 **60** Not Applicable T1 Assembly, Mark-up Applied

@ Bottom. D-Cell, NiMH, Nickel Substrate Not Applicable Not Applicable **3600 0**  **1 1**  0.02243 **$21.94 $0.00**  **$0.00 $0.00**  **$0.49 $0.00**  **$0.00 $0.49**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.49 $29.52**  **$29.52**

11 2D Negative Electrode Purchased in Raw Material,

Carbon Black 140301-N0402-01-814 **60** Not Applicable T1 Assembly, Mark-up Applied

@ Bottom. D-Cell, NiMH, Carbon Black Not Applicable Not Applicable **3600 0**  **1 1**  0.00040 **$9.00 $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 $0.22**  **$0.22**

12 2E Negative Electrode Purchased in Raw Material,

Negative Powder 140301-N0402-01-815 **60** Not Applicable T1 Assembly, Mark-up Applied

@ Bottom. D-Cell, NiMH, Negative Powder Not Applicable Not Applicable **3600 0**  **1 1**  0.08086 **$19.54 $0.00**  **$0.00 $0.00**  **$1.58 $0.00**  **$0.00 $1.58**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.58 $94.80**  2.09 $ 125.54

$ **$94.80**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 3 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 High Assembly Complexity**



## System Description: **Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)** 

## Annual Component Volume: Shipping Method:

**Component Description: Part Number:**  **140301-N0402-01-999** 

## We ekly Component Volume: Packaging Specification: **N/A Considered WIP (work in progress)**



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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **450,000**

**V Battery Module - Nickel Metal Hydride, Traction Battery Assembly (3 battery modules, 2 sub-modules per modules, 10**

**cells per sub-module, total of 60 cells)** 

### 9,574

**10**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **North America**

**North America**

**FOB Ship Point 47** 

**450,000**

**1 Mild Series Gasoline Hybrid** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

13 **0 #####**  **0 1**  **1** 0.00000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 3A Purchased in Raw Material, Electrolyte 140301-N0402-01-820 **60** Not Applicable T1 Assembly, Mark-up Applied

@ Bottom. D-Cell, NiMH, Electrolyte Not Applicable Not Applicable **3600 0**  **1 1**  0.03652 **$0.20 $0.00**  **$0.00 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.01 $0.44**  **$0.44**

15 3B Purchased in Raw Material, Asphalt 140301-N0402-01-821 **60** Not Applicable T1 Assembly, Mark-up Applied

@ Bottom. D-Cell, NiMH, Asphalt Not Applicable Not Applicable **3600 0**  **1 1**  0.00002 **$15.37 $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 $0.02**  **$0.02**

16 3C Purchased in Raw Material, PP Separator 140301-N0402-01-822 **60** Not Applicable T1 Assembly, Mark-up Applied

@ Bottom. D-Cell, NiMH, PP Separator Not Applicable Not Applicable **3600 0**  **1 1**  0.05099 **$3.75 $0.00**  **$0.00 $0.00**  **$0.19 $0.00**  **$0.00 $0.19**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.19 $11.47**  0.20 $ 11.93

$ **$11.47**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

5 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

6 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

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

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

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

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

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

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to

T1 or OEM for Final or Sub

- Assembly. In addition component material cost is

accounted for in T1 quote sheet. Thus component cost will only be included for

Mark

- up Calculations.

"Alpha

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

Supplier for Subassembly.

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

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

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

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

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

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

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

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

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

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

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



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 4 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 High Assembly Complexity**



## System Description: **Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)** 

## Annual Component Volume: Shipping Method:

**Component Description: Part Number:**  **140301-N0402-01-999** 

## We ekly Component Volume: Packaging Specification: **N/A Considered WIP (work in progress)**



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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **450,000**

**V Battery Module - Nickel Metal Hydride, Traction Battery Assembly (3 battery modules, 2 sub-modules per modules, 10**

**cells per sub-module, total of 60 cells)** 

### 9,574

**10**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **North America**

**North America**

**FOB Ship Point 47** 

**450,000**

**1 Mild Series Gasoline Hybrid** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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

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

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

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

**Material**

**$238.76**

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

**Mark-up $290.02** 

**T1 or OEM Total Manufacturing Cost: $238.76**  **$14.78 $36.49**  **$290.02 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$290.02 3**  **1**



### Notes: **T1 or OEM Total Manufacturing Cost: $238.76**  **$14.78 $36.49**  **$290.02 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$290.02**

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

----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%

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

----- ----- ----- **$2.03 $20.30**  **$23.20 $11.60**  **$57.13**

**Base Cost Impact to Vehicle: $238.76**  **$14.78 $36.49**  **$290.02 $2.03**  **$20.30 $23.20**  **$11.60 $57.13**  **$347.16 $4**  **$256**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $347.16** 



### $5.79 /Cell

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment**

**(%) Total # of** 

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging**

**Cost per**

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



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



### Packaging Cost Total: **$0.000** 

### PACKAGING CALCULATIONS:

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers: **Notes:**

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 5 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

1A Main Cell Assembly 140301-N0402-01-875

4A Formation Process 140301-N0402-01-876

5A Thermal Cycle & Functional Test 140301-N0402-01-877



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **k t** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$3.21 $8.91**  **$12.12 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Automated assembly line, wind, weld positive and negative electrodes, insert into casing, weld bottom

electrode, place insulator, groove can, tar can, add electrolyte, weld cover and close, crimp into position x3,

voltage test.

Automated Cap Subassembly line feeds final cap assembly line **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53**

- 18 1 1 **1.0 2.0** 

**$1.93 $16.61**  **$18.54 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Automated part load, unload, 36 formation cabinets per line, 12 hour formation schedule. 3 direct

operators monitoring process per line **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53**

- 3 1 1 **1.0 2.0** 

**$1.93 $1.31**  **$3.24 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Automated part load, unload, conveyor feed from formation line, minumum 24 hour heat soak, functional

test fo rejects, sort per group per voltage specification. 6 test stations, 3 operators per line. **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53**

- 2 1 1 **1.0 2.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Minimum Calculated Cycles Time **Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

MOH line assumptions, equipment

balanced to produce 1 cell/second.



## Purchase Part - High Impact Item (Full Cost Mapping) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### MOH line assumptions, equipment

balanced to produce 1 cell/second. Lines configured to produced 3600 batteries and

hour. Two Lines required to meet capacity

requirements.

1A Cathode Electrode Material Preparation 140301-N0402-01-850

1B Cathode Electrode Coating 140301-N0402-01-851

1C Cathode Electrode Compaction 140301-N0402-01-852

2A Anode Electrode Material Preparation 140301-N0402-01-853

2B Anode Electrode Coating 140301-N0402-01-854

2C Anode Electrode Compaction 140301-N0402-01-855 **$1.28 $0.82**  **$2.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Semiautomated mixing line **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53**

- 2 1 1 **1.0 2.0** 

**$1.28 $2.99**  **$4.28 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Automated unwind, coat, cure, slit electrode line **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53**

- 16 1 1 **1.0 2.0** 

**$1.28 $1.00**  **$2.28 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Automated compaction line, electrode sizing, seam weld collector strip, cut to length **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53**

- 7 1 1 **1.0 2.0** 

**$1.28 $1.14**  **$2.43 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Semiautomated mixing line **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53**

- 2 1 1 **1.0 2.0** 

**$1.28 $2.89**  **$4.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Automated unwind, coat, cure, slit electrode line **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53**

- 15 1 1 **1.0 2.0** 

**$1.28 $0.82**  **$2.11 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Automated compaction line, electrode sizing, seam weld collector strip, cut to length **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53**

- 6 1 1 **1.0 2.0** 



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 6 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **k t** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 



### Minimum Calculated Cycles Time **Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 2.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 



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

1A Positive Electrode Purchased in Raw Material,

PAS (Binder) 140301-N0402-01-800

1B Positive Electrode Purchased in Raw Material,

Positive Substrate 140301-N0402-01-801

1C Positive Electrode Purchased in Raw Material,

Nickel Strip 140301-N0402-01-802

1D Positive Electrode Purchased in Raw Material,

Positive Powder 140301-N0402-01-803

1E Positive Electrode Purchased in Raw Material,

Cobalt Powder 140301-N0402-01-804

1F Positive Electrode Purchased in Raw Material,

Cobalt Oxide 140301-N0402-01-805

Negative Electrode Purchased in Raw Material, 

### Section Modified to Capture Raw Material Costs for Postive and Negative Electrodes **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.03 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  This section addresses raw material costs only. Added to this section rather than commodity purchase

part section to support sensitivity analysis on material costs **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53** 1 1 1 1 **1.0 1.0** 

**$0.00 $0.00**  **$33.39 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  This section addresses raw material costs only. Added to this section rather than commodity purchase

part section to support sensitivity analysis on material costs **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53** 1 1 1 1 **1.0 1.0** 

**$0.00 $0.00**  **$5.95 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  This section addresses raw material costs only. Added to this section rather than commodity purchase

part section to support sensitivity analysis on material costs **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53** 1 1 1 1 **1.0 1.0** 

**$0.00 $0.00**  **$47.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  This section addresses raw material costs only. Added to this section rather than commodity purchase

part section to support sensitivity analysis on material costs **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53** 1 1 1 1 **1.0 1.0** 

**$0.00 $0.00**  **$6.55 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  This section addresses raw material costs only. Added to this section rather than commodity purchase

part section to support sensitivity analysis on material costs **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53** 1 1 1 1 **1.0 1.0** 

**$0.00 $0.00**  **$8.04 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  This section addresses raw material costs only. Added to this section rather than commodity purchase

part section to support sensitivity analysis on material costs **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53** 1 1 1 1 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Section does not apply.

2A Negative Electrode Purchased in Raw Material,

Carboxyl Methyl Cellulose (Thickener) 140301-N0402-01-810

2B Negative Electrode Purchased in Raw Material,

PTFE Binder 140301-N0402-01-811

2C Negative Electrode Purchased in Raw Material,

Nickel Substrate 140301-N0402-01-812

2D Negative Electrode Purchased in Raw Material,

Carbon Black 140301-N0402-01-814

2E Negative Electrode Purchased in Raw Material,

Negative Powder 140301-N0402-01-815 **$0.00 $0.00**  **$0.26 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  This section addresses raw material costs only. Added to this section rather than commodity purchase

part section to support sensitivity analysis on material costs **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53** 1 1 1 1 **1.0 1.0** 

**$0.00 $0.00**  **$0.74 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  This section addresses raw material costs only. Added to this section rather than commodity purchase

part section to support sensitivity analysis on material costs **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53** 1 1 1 1 **1.0 1.0** 

**$0.00 $0.00**  **$29.52 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  This section addresses raw material costs only. Added to this section rather than commodity purchase

part section to support sensitivity analysis on material costs **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53** 1 1 1 1 **1.0 1.0** 

**$0.00 $0.00**  **$0.22 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  This section addresses raw material costs only. Added to this section rather than commodity purchase

part section to support sensitivity analysis on material costs **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53** 1 1 1 1 **1.0 1.0** 

**$0.00 $0.00**  **$94.80 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  This section addresses raw material costs only. Added to this section rather than commodity purchase

part section to support sensitivity analysis on material costs **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53** 1 1 1 1 **1.0 1.0** 



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 7 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

3A Purchased in Raw Material, Electrolyte 140301-N0402-01-820

3B Purchased in Raw Material, Asphalt 140301-N0402-01-821

3C Purchased in Raw Material, PP Separator 140301-N0402-01-822 

### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **k t** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 



### Minimum Calculated Cycles Time **Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.44 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  This section addresses raw material costs only. Added to this section rather than commodity purchase

part section to support sensitivity analysis on material costs **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53** 1 1 1 1 **1.0 1.0** 

**$0.00 $0.00**  **$0.02 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  This section addresses raw material costs only. Added to this section rather than commodity purchase

part section to support sensitivity analysis on material costs **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53** 1 1 1 1 **1.0 1.0** 

**$0.00 $0.00**  **$11.47 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  This section addresses raw material costs only. Added to this section rather than commodity purchase

part section to support sensitivity analysis on material costs **5 2**  **10 100**  **47 4700**  **5745 0.63**  **85% 6758**  **0.53** 1 1 1 1 **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 8 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **k t** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 



### Minimum Calculated Cycles Time **Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

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

**Total**

**$14.78 $36.49**  **$290.02 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$290.02 2** 



### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 9 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

1A Main Cell Assembly 140301-N0402-01-875

4A Formation Process 140301-N0402-01-876

5A Thermal Cycle & Functional Test 140301-N0402-01-877



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**7200 0.50**  10.00

**7200 0.50**  6.00

**7200 0.50**  6.00

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



## Purchase Part - High Impact Item (Full Cost Mapping) **#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

1A Cathode Electrode Material Preparation 140301-N0402-01-850

1B Cathode Electrode Coating 140301-N0402-01-851

1C Cathode Electrode Compaction 140301-N0402-01-852

2A Anode Electrode Material Preparation 140301-N0402-01-853

2B Anode Electrode Coating 140301-N0402-01-854

2C Anode Electrode Compaction 140301-N0402-01-855 **7200 0.50**  4.00

**7200 0.50**  4.00

**7200 0.50**  4.00

**7200 0.50**  4.00

**7200 0.50**  4.00

**7200 0.50**  4.00



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 10 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



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

1A Positive Electrode Purchased in Raw Material,

PAS (Binder) 140301-N0402-01-800

1B Positive Electrode Purchased in Raw Material,

Positive Substrate 140301-N0402-01-801

1C Positive Electrode Purchased in Raw Material,

Nickel Strip 140301-N0402-01-802

1D Positive Electrode Purchased in Raw Material,

Positive Powder 140301-N0402-01-803

1E Positive Electrode Purchased in Raw Material,

Cobalt Powder 140301-N0402-01-804

1F Positive Electrode Purchased in Raw Material,

Cobalt Oxide 140301-N0402-01-805

Negative Electrode Purchased in Raw Material, 

### Section Modified to Capture Raw Material Costs for Postive and Negative Electrodes **#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**3600 1.00** 

-

**3600 1.00** 

-

**3600 1.00** 

-

**3600 1.00** 

-

**3600 1.00** 

-

**3600 1.00** 

-

**#DIV/0! #DIV/0!** 

-

2A Negative Electrode Purchased in Raw Material,

Carboxyl Methyl Cellulose (Thickener) 140301-N0402-01-810

2B Negative Electrode Purchased in Raw Material,

PTFE Binder 140301-N0402-01-811

2C Negative Electrode Purchased in Raw Material,

Nickel Substrate 140301-N0402-01-812

2D Negative Electrode Purchased in Raw Material,

Carbon Black 140301-N0402-01-814

2E Negative Electrode Purchased in Raw Material,

Negative Powder 140301-N0402-01-815 **3600 1.00** 

-

**3600 1.00** 

-

**3600 1.00** 

-

**3600 1.00** 

-

**3600 1.00** 

-



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 11 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

3A Purchased in Raw Material, Electrolyte 140301-N0402-01-820

3B Purchased in Raw Material, Asphalt 140301-N0402-01-821

3C Purchased in Raw Material, PP Separator 140301-N0402-01-822**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**3600 1.00** 

-

**3600 1.00** 

-

**3600 1.00** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 12 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year):

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV):

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine:

**System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)**  

## Annual Component Volume:

**Component Description: V Battery Module - Nickel Metal Hydride, Traction Battery Assembly**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life:

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB)**

A 

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

1 V Cell Electrode Wrapper 140303-N0402-35 **60** Integrate Plates (+ / -) and separator paper (purchased-see below) T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, HC **6863 15.25**  **61 1**  0.000 **$0.00 $29.83**  **$150.00 $9,150.00**  **$0.00 $0.07**  **$1.33 $1.40**  **0.00% 0.00%** 

2 V Electrode Plate Postive 140303-N0402-36 **840** Apply foil to binder / cut / seam weld T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, HC **94629 46**  **92 1**  0.000 **$0.00 $29.83**  **$150.00 $13,800.00**  **$0.00 $0.01**  **$0.15 $0.16**  **0.00% 0.00%** 

3 V Slurry - Binder Cathode 140303-N0402-37 **840** Mix / Roll / Coat / Dry T1 Assembly, Mark-up Applied @ Bottom. **Slurry of NiMH-Carbon-Binder-Plasticizer** Electrical Assembly Elec. Assembly, HC **96225 47**  **47 2**  0.008 **$16.29 $29.83**  **$150.00 $14,100.00**  **$0.13 $0.01**  **$0.15 $0.29**  **0.00% 0.00%** 

4 V Electrode Plate Negative 140303-N0402-39 **840** Apply foil to binder / cut / seam weld T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, HC **94629 46**  **92 1**  0.000 **$0.00 $29.83**  **$150.00 $13,800.00**  **$0.00 $0.01**  **$0.15 $0.16**  **0.00% 0.00%** 

5 V Carbon Slurry - Anode Electrode 140303-N0402-40 **840** Mix / Roll / Coat / Dry T1 Assembly, Mark-up Applied @ Bottom. **Slurry of Graphite-Carbon-Binder-Plasticizer** Electrical Assembly Elec. Assembly, HC **96225 47**  **47 2**  0.008 **$5.95 $29.83**  **$150.00 $14,100.00**  **$0.05 $0.01**  **$0.15 $0.21**  **0.00% 0.00%** 



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Series Gasoline Hybrid**

**MARK-UP COSTS 9,574** 

**10 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Quote Modification Q**  **uote** 

### Differential Quote (Quote S **um mary includes costin**  **g for both T echnology Packages)** 

1 V Electrode Separator Paper 140399-N0402-11 **60** Microporous Polyolefin Film per cell "stack" = 65mm W x 3,022mm L (10') @ $0.03/ft S

2 V Electrode Foil- Postive Cathode 140303-N0402-38 **840** S

3 V Electrode Copper Foil - Neg. (Anode) 140303-N0402-41 **840** S

**Material Labor**  **Burden TMC**  **Scrap SG&A** 

**T1 or OEM Total Manufacturing Cost: $172.84**  **$52.81 $571.17**  **$796.82 $0.00**  **$0.00**

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

----- ----- ----- ----- 0.70% 7.00%

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

----- ----- ----- **$5.58 $55.78** 

**Base Cost Impact to Vehicle: $172.84**  **$52.81 $571.17**  **$796.82 $5.58**  **$55.78**

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment (%) Total # of** 

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 

### PACKAGING CALCULATIONS:

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers: "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

- Assembly.

**Reference Packaging Database for Additonal Infromation**

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad **Rack/Pallet Investment Amortization: $0.000**  **$0 0.00%**  **2,250,000 60**  **5.00%** $0 **58**

**Packaging**

**Cost per**

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1 Pads** 

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack**



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



### Packaging Cost Total: **$0.000** 

### Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year):

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV):

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine:

**System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)**  

## Annual Component Volume:

**Component Description: V Battery Module - Nickel Metal Hydride, Traction Battery Assembly**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life:

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) GENERAL COMPONENT INFORMATION**  **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Series Gasoline Hybrid** 

**MARK-UP COSTS 9,574** 

**10 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Quote Modification Q**  **uote** 

### Differential Quote (Quote S **um mary includes costin**  **g for both T echnology Packages)** 



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

V Cell Electrode Wrapper 140303-N0402-35

V Electrode Plate Postive 140303-N0402-36

V Slurry - Binder Cathode 140303-N0402-37

V Electrode Plate Negative 140303-N0402-39

V Carbon Slurry - Anode Electrode 140303-N0402-40



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

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc. 

## OEM Plant Location:

Supplier Plant Location:

OEM/T1 Classification: **T1 High Assembly Complexity**



## Shipping Method:

Packaging Specification:

Production Year: **2008/2009**

**Profit**

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark-up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift**

**0.00% 0.00%**  **0.00% $0.00**  **$1.40 $83.98**  **$0.00 $3.98**  **$80.00 $83.98**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Automated placement of finished plates (+ / -) onto separator paper, wrap, seam weld, and fold **5 2**  **10**

**0.00% 0.00%**  **0.00% $0.00**  **$0.16 $134.68**  **$0.00 $12.18**  **$122.50 $134.68**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Apply foil to binder / cut / seam weld **5 2**  **10**

**0.00% 0.00%**  **0.00% $0.00**  **$0.29 $244.80**  **$109.47 $12.24**  **$123.09 $244.80**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** See tabs labeled "Plate Cycle Time Estimate" and "Slurry - Anode & Cathode" for calculations. **5 2**  **10**

**0.00% 0.00%**  **0.00% $0.00**  **$0.16 $134.68**  **$0.00 $12.18**  **$122.50 $134.68**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Apply foil to binder / cut / seam weld **5 2**  **10**

**0.00% 0.00%**  **0.00% $0.00**  **$0.21 $175.29**  **$39.97 $12.24**  **$123.09 $175.29**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** See tabs labeled "Plate Cycle Time Estimate" and "Slurry - Anode & Cathode" for calculations. **5 2**  **10**

**Supplier**

**Account**

**Cost Purchase** 

**Price/ Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item** 

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**TOTAL COSTS TOOLING & INVESTMENT**  

### Projected Operating Pattern **MARK-UP COSTS MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity North America** 

**North America**

**FOB Ship Point**

V Electrode Separator Paper 140399-N0402-11

V Electrode Foil- Postive Cathode 140303-N0402-38

V Electrode Copper Foil - Neg. (Anode) 140303-N0402-41 **Cost PIA**  **End Item**

**$0.00** $0.30 **$0.00 $18.00**  **$18.00 $18.00** 

**$0.00** $0.00063 **$0.00 $0.53**  **$0.53 $0.53** 

**$0.00** $0.00580 **$0.00 $4.87**  **$4.87 $4.87** 

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

**Total**

**$172.84 $52.81**  **$571.17 $796.82**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**Profit ED&T**  **Total**

**Mark-up $796.82**  **$796.82**

**$0.00 $0.00**  **$0.00 $796.82** 

8.00% 4.00% 19.70%

**$63.75 $31.87**  **$156.97**

**$63.75 $31.87**  **$156.97 $953.80**  **$0 $0** 

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $953.80** **N u** **m b** **e r** **o f** **P a** **r t** **s p** **e r** **P a** **l l** **e t** **/ R** **a c** **k S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)** 

### $15.90

1000 **6 57447**  **3 1**  **2**



### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**

1000 **6 57447** 

**Other #3**

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**

$0.00 0



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc. 

## OEM Plant Location:

Supplier Plant Location:

OEM/T1 Classification: **T1 High Assembly Complexity**



## Shipping Method:

Packaging Specification:

Production Year: **2008/2009**

**Profit**

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark-up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Process Information**  **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**TOTAL COSTS TOOLING & INVESTMENT**  

### Projected Operating Pattern **MARK-UP COSTS MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity North America** 

**North America**

**FOB Ship Point**

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

V Cell Electrode Wrapper 140303-N0402-35

V Electrode Plate Postive 140303-N0402-36

V Slurry - Binder Cathode 140303-N0402-37

V Electrode Plate Negative 140303-N0402-39

V Carbon Slurry - Anode Electrode 140303-N0402-40



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

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Hrs./

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** **R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**100 47**  **4700 5745**  **0.63 85%**  **6758 0.53** 

- 1 1 32.00 **1.0 61.0**  **6863 0.52**  15.25

**100 47**  **4700 80426**  **0.04 85%**  **94618 0.04** 

- 1 1 3.50 **1.0 92.0**  **94629 0.04**  46.00

**100 47**  **4700 80426**  **0.04 85%**  **94618 0.04** 

- 2 1 1.76 **2.0 47.0**  **96225 0.04**  47.00

**100 47**  **4700 80426**  **0.04 85%**  **94618 0.04** 

- 1 1 3.50 **1.0 92.0**  **94629 0.04**  46.00

**100 47**  **4700 80426**  **0.04 85%**  **94618 0.04** 

- 2 1 1.76 **2.0 47.0**  **96225 0.04**  47.00 

### Projected Operating Pattern **MANUFACTURING ASSUMPTIONS**

**Project Process Requirement Minimum Calculated Cycles Time** 

V Electrode Separator Paper 140399-N0402-11

V Electrode Foil- Postive Cathode 140303-N0402-38

V Electrode Copper Foil - Neg. (Anode) 140303-N0402-41



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Hrs./

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** **R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s**  

### Projected Operating Pattern **MANUFACTURING ASSUMPTIONS**

**Project Process Requirement Minimum Calculated Cycles Time** 

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 High Assembly Complexity**



## System Description: **Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)** 

## Annual Component Volume: Shipping Method:

**Component Description: V Battery Control PCB**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** 



### A 

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

1 V Bat PCB Testing **1** Functional Test, Medium Boards with 160-250

Chips/side and a Max of 70 odd form

components. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly EOL Func.Test, Medium Content **120 1**  **1 1**  0.000 **$0.00 $29.83**  **$28.18 $28.18**  **$0.00 $0.25**  **$0.23 $0.48**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.48 $0.48** 

2 V Bat PCB Elec Depanel Router **1** De-Panel-Router Station, In-Line, Complex

geometries an/or vibration sensitive

boards/inverta delta boards. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly De-Panel, In-Line, Router **720 1**  **1 1**  0.000 **$0.00 $29.83**  **$24.38 $24.38**  **$0.00 $0.04**  **$0.03 $0.08**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.08 $0.08** 

3 V Bat PCB BOTTOM SIDE - SURFACE MOUNT **1** DEK Screen Printer T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly SMT, Low Content **600 0.5**  **1 1**  0.000 **$0.00 $29.83**  **$212.63 $212.63**  **$0.00 $0.02**  **$0.35 $0.38**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.38 $0.38** 

4 V Bat PCB TOP SIDE - SURFACE MOUNT **1** DEK Screen Printer T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly SMT, Medium Content **400 0.5**  **1 1**  0.000 **$0.00 $29.83**  **$218.25 $218.25**  **$0.00 $0.04**  **$0.55 $0.58**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.58 $0.58** 

5 V Bat PCB Conformal Coating **1** PVA Coating Applicator T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Conformal Coat, UV Cure **3600 1**  **1 1**  0.000 **$0.00 $29.83**  **$28.33 $28.33**  **$0.00 $0.01**  **$0.01 $0.02**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.02 $0.02**  

### 9,574

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Series Gasoline Hybrid**

**MARK-UP COSTS TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Q uote**  **Modification Q uote**  

### Di **ffe ren**  **tial Quote (Quote S um**  **mary in clu**  **des costing for both T echnology Packages)** 

5 V Bat PCB Conformal Coating **1** PVA Coating Applicator T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Conformal Coat, UV Cure **3600 1**  **1 1**  0.000 **$0.00 $29.83**  **$28.33 $28.33**  **$0.00 $0.01**  **$0.01 $0.02**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.02 $0.02** 



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 IC - Surface Mount MC9S12DG128M PV-ND **1** S **$0.00** $3.50 **$0.00 $3.50** 

2 PhotoMOS - Surface Mount 255-2130-2-ND **3** S **$0.00** $3.72 **$0.00 $11.16** 

3 IC - Surface Mount 495-1868-2-ND **1** S **$0.00** $0.43 **$0.00 $0.43** 

4 IC - Surface Mount TLE42754D-ND **1** S **$0.00** $0.87 **$0.00 $0.87** 

5 IC - Surface Mount 497-1548-1-ND **1** S **$0.00** $0.32 **$0.00 $0.32** 

6 MOSFET - Surface Mount IPS041L-ND **1** S **$0.00** $0.13 **$0.00 $0.13** 

7 Optoisolators - Surface Mount 160-1305-5-ND **1** S **$0.00** $0.10 **$0.00 $0.10** 

8 Optoisolators - Surface Mount 516-1731-1-ND **1** S **$0.00** $0.27 **$0.00 $0.27** 

9 Aluminum Capacitor - Surface Mount PCE3155TR-ND-1 **3** S **$0.00** $0.32 **$0.00 $0.96** 

10 IC - Surface Mount 296-17563-2-ND **1** S **$0.00** $0.24 **$0.00 $0.24** 

11 IC - Surface Mount 497-1170-2-ND **1** S **$0.00** $0.26 **$0.00 $0.26** 

12 CRYSTAL - Surface Mount 631-1011-6-ND **1** S **$0.00** $0.31 **$0.00 $0.31** 

13 IC - Surface Mount OPA343UA/2K5-ND **2** S **$0.00** $0.67 **$0.00 $1.34** 

14 IC - Hex Inverting Trigger MM74HC14SJX-ND **2** S **$0.00** $0.10 **$0.00 $0.20** 

15 Capacitors Capacitors **21** S **$0.00** $0.01 **$0.00 $0.21** 

16 Resistors Resistors **26** S **$0.00** $0.01 **$0.00 $0.26** 

17 DC DC Converter - Thru Hole 811-1556-5-ND **1** S **$0.00** $10.37 **$0.00 $10.37** 

18 IC - Surface Mount 296-17563-2-ND **4** S **$0.00** $0.24 **$0.00 $0.96** 

19 Optoisolator - Surface Mount 516-1731-1-ND **4** S **$0.00** $0.27 **$0.00 $1.08** 

20 PhotoMOS � - Surface Mount 255-2130-2-ND **3** S **$0.00** $3.72 **$0.00 $11.16** 

21 MOSFET - Surface Mount IPS041L-ND **1** S **$0.00** $0.13 **$0.00 $0.13** 

22 IC - Hex Inverting Trigger MM74HC14SJX-ND **1** S **$0.00** $0.10 **$0.00 $0.10** 

23 Capacitors Capacitors **47** S **$0.00** $0.01 **$0.00 $0.47** 

24 Resistors Resistors **43** S **$0.00** $0.01 **$0.00 $0.43** 

25 Power Connector - Thru Hole WM3809-ND **1** S **$0.00** $1.41 **$0.00 $1.41**  

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to

T1 or OEM for Final or Sub

- Assembly. In addition component material cost is

accounted for in T1 quote sheet. Thus component cost will only be included for

Mark

- up Calculations.

"Alpha

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

Supplier for Subassembly.

25 Power Connector - Thru Hole WM3809-ND **1** S **$0.00** $1.41 **$0.00 $1.41** 

26 V Bat PCB Bareboard Commodity Pricing **1** S **$0.00** $1.99 **$0.00 $1.99** 

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

**Mark-up $50.20** 

**T1 or OEM Total Manufacturing Cost: $48.66**  **$0.36 $1.18**  **$50.20 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$50.20**

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

----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%

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

----- ----- ----- **$0.35 $3.51**  **$4.02 $2.01**  **$9.89 3**  **1**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 High Assembly Complexity**



## System Description: **Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)** 

## Annual Component Volume: Shipping Method:

**Component Description: V Battery Control PCB**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### 9,574

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Series Gasoline Hybrid**

**MARK-UP COSTS TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Q uote**  **Modification Q uote**  

### Di **ffe ren**  **tial Quote (Quote S um**  **mary in clu**  **des costing for both T echnology Packages)** 

**Base Cost Impact to Vehicle: $48.66**  **$0.36 $1.18**  **$50.20 $0.35**  **$3.51 $4.02**  **$2.01 $9.89**  **$60.09 $0** 

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $60.09** 

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment**

**(%) Total # of** 

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)** 

### PACKAGING CALCULATIONS:

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers: **Reference Packaging Database for Additonal Infromation**

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)**C o** **s t** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **T o** **t a** **l N** **u m** **b e** **r o** **f P** **a l** **l e** **t s** **/ R** **a c** **k s** **R e** **q u** **i r** **e d** **N u** **m b** **e r** **o f** **P a** **r t** **s p** **e r** **P a** **l l** **e t** **/ S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging**

**Cost per**

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



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



### Packaging Cost Total: **$0.000** 

### Number of Layers: Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

V Bat PCB Testing

V Bat PCB Elec Depanel Router

V Bat PCB BOTTOM SIDE - SURFACE MOUNT

V Bat PCB TOP SIDE - SURFACE MOUNT

V Bat PCB Conformal Coating



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e**

**$0.00 $0.25**  **$0.23 $0.48**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Functional Test, Medium Boards with 160-250 Chips/side and a Max of 70 odd

form components. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 30 1

**$0.00 $0.04**  **$0.03 $0.08**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** De-Panel-Router Station, In-Line, Complex geometries an/or vibration sensitive

boards/inverta delta boards. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 5 1

**$0.00 $0.02**  **$0.35 $0.38**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** DEK Screen Printer **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 6 1

**$0.00 $0.04**  **$0.55 $0.58**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** DEK Screen Printer **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 9 1

**$0.00 $0.01**  **$0.01 $0.02**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** PVA Coating Applicator **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1 1 

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Process Information**  **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**TOOLING & INVESTMENT**

V Bat PCB Conformal Coating



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

IC - Surface Mount MC9S12DG128M PV-ND

PhotoMOS - Surface Mount 255-2130-2-ND

IC - Surface Mount 495-1868-2-ND

IC - Surface Mount TLE42754D-ND

IC - Surface Mount 497-1548-1-ND

MOSFET - Surface Mount IPS041L-ND

Optoisolators - Surface Mount 160-1305-5-ND

Optoisolators - Surface Mount 516-1731-1-ND

Aluminum Capacitor - Surface Mount PCE3155TR-ND-1

IC - Surface Mount 296-17563-2-ND

IC - Surface Mount 497-1170-2-ND

CRYSTAL - Surface Mount 631-1011-6-ND

IC - Surface Mount OPA343UA/2K5-ND

IC - Hex Inverting Trigger MM74HC14SJX-ND

Capacitors Capacitors

Resistors Resistors

DC DC Converter - Thru Hole 811-1556-5-ND

IC - Surface Mount 296-17563-2-ND

Optoisolator - Surface Mount 516-1731-1-ND

PhotoMOS � - Surface Mount 255-2130-2-ND

MOSFET - Surface Mount IPS041L-ND

IC - Hex Inverting Trigger MM74HC14SJX-ND

Capacitors Capacitors

Resistors Resistors

Power Connector - Thru Hole WM3809-ND **$0.00 $0.01**  **$0.01 $0.02**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** PVA Coating Applicator **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1 1

**$3.50 $3.50** 

**$11.16 $11.16** 

**$0.43 $0.43** 

**$0.87 $0.87** 

**$0.32 $0.32** 

**$0.13 $0.13** 

**$0.10 $0.10** 

**$0.27 $0.27** 

**$0.96 $0.96** 

**$0.24 $0.24** 

**$0.26 $0.26** 

**$0.31 $0.31** 

**$1.34 $1.34** 

**$0.20 $0.20** 

**$0.21 $0.21** 

**$0.26 $0.26** 

**$10.37 $10.37** 

**$0.96 $0.96** 

**$1.08 $1.08** 

**$11.16 $11.16** 

**$0.13 $0.13** 

**$0.10 $0.10** 

**$0.47 $0.47** 

**$0.43 $0.43** 

**$1.41 $1.41**  Power Connector - Thru Hole WM3809-ND

V Bat PCB Bareboard Commodity Pricing **$1.41 $1.41** 

**$1.99 $1.99** 

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

**Total**

**$48.66 $0.36**  **$1.18 $50.20**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**$50.20 2** 



### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e** 

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Process Information**  **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**TOOLING & INVESTMENT**

**$0**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

V Bat PCB Testing

V Bat PCB Elec Depanel Router

V Bat PCB BOTTOM SIDE - SURFACE MOUNT

V Bat PCB TOP SIDE - SURFACE MOUNT

V Bat PCB Conformal Coating



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**

1 30 **1.0 1.0**  **120 30.00**  1.00

1 5 **1.0 1.0**  **720 5.00**  1.00

1 6 **1.0 1.0**  **600 6.00**  0.50

1 9 **1.0 1.0**  **400 9.00**  0.50

1 1 **1.0 1.0**  **3600 1.00**  1.00 

### Project Process Requirement

V Bat PCB Conformal Coating



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

IC - Surface Mount MC9S12DG128M PV-ND

PhotoMOS - Surface Mount 255-2130-2-ND

IC - Surface Mount 495-1868-2-ND

IC - Surface Mount TLE42754D-ND

IC - Surface Mount 497-1548-1-ND

MOSFET - Surface Mount IPS041L-ND

Optoisolators - Surface Mount 160-1305-5-ND

Optoisolators - Surface Mount 516-1731-1-ND

Aluminum Capacitor - Surface Mount PCE3155TR-ND-1

IC - Surface Mount 296-17563-2-ND

IC - Surface Mount 497-1170-2-ND

CRYSTAL - Surface Mount 631-1011-6-ND

IC - Surface Mount OPA343UA/2K5-ND

IC - Hex Inverting Trigger MM74HC14SJX-ND

Capacitors Capacitors

Resistors Resistors

DC DC Converter - Thru Hole 811-1556-5-ND

IC - Surface Mount 296-17563-2-ND

Optoisolator - Surface Mount 516-1731-1-ND

PhotoMOS � - Surface Mount 255-2130-2-ND

MOSFET - Surface Mount IPS041L-ND

IC - Hex Inverting Trigger MM74HC14SJX-ND

Capacitors Capacitors

Resistors Resistors

Power Connector - Thru Hole WM3809-ND 1 1 **1.0 1.0**  **3600 1.00**  1.00

Power Connector - Thru Hole WM3809-ND

V Bat PCB Bareboard Commodity Pricing



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Project Process Requirement

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification:

**System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)**  

## Annual Component Volume: Shipping Method:

**Component Description: V Battery Disconnect Unit, Traction Battery Assembly**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life:

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB)**

A 

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

1 V Battery Disconnect Unit 140303-N0402-01 **1** Final Assembly & Integration - Battery Disconnect Unit T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, HC **164 4**  **1 4**  0.535 **$0.00 $29.83**  **$150.00 $600.00**  **$0.00 $0.73**  **$3.67 $4.40**  **0.00% 0.00%**  **0.00%**

2 V Chassis - Battery Disconn Unit 140303-N0402-02 **1** Insert Mold two (2) terminal studs 281.92mm x 110.1mm x 63.1mm (725 ton press) T1 Assembly, Mark-up Applied @ Bottom. HDPE BM Grade Mold/Cast/Sinter Operator Inject. Mold, LS **257 1**  **1 1**  0.535 **$0.72 $41.48**  **$151.77 $151.77**  **$0.39 $0.16**  **$0.59 $1.14**  **0.00% 0.00%**  **0.00%**

3 V Stud - Positive Terminal 140303-N0402-03 **1** THEO-TL-05BB, Bar Capacity=Ø51mm T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Bar Lathe/Turning Operator DS-CNC Turning, SS, BF, QA **200 0.25**  **1 1**  0.204 **$1.65 $38.97**  **$37.93 $37.93**  **$0.34 $0.05**  **$0.19 $0.57**  **0.00% 0.00%**  **0.00%**

4 V Stud - Negative Terminal 140303-N0402-04 **1** THEO-TL-05BB, Bar Capacity=Ø51mm T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Bar Lathe/Turning Operator DS-CNC Turning, SS, BF, QA **200 0.25**  **1 1**  0.170 **$1.65 $38.97**  **$37.93 $37.93**  **$0.28 $0.05**  **$0.19 $0.52**  **0.00% 0.00%**  **0.00%**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **9,574**

**10 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Series Gasoline Hybrid**

**MARK-UP COSTS** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Q uote**  **Modification Q uote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

1 V Module - Auto Batt. Discharge 140303-N0402-06 **1** High Capacity Shut-Off Relay AEB310012 S 

### http://pewa.panasonic.com/pcsd/product/auto/pdf/mech_eng_eb.pdf

2 V Screw - Battery Discharge Mod. 140380-N0402-08 **2** S

3 V Bus Bar - Auto Discharge 140303-N0402-07 **1** S

4 V Nut - Bus Bar Auto Discharge 140380-N0402-09 **1** S

5 V Stud - Fusable Link 140303-N0402-08 **1** S

6 V Fuse - Battery Disconnect Box 140303-N0402-09 **1** S

7 V Nut Fusable link 140380-N0402-10 **1** S

8 V Signal Module - Battery 140303-N0402-10 **1** Instantaneous Ouput Relay S 

### http://www.lem.com/hq/en/component/option,com_catalog/task,displaymodel/id,90.B6.99.014.0/

9 V Screw - Batt. Signal Module 140380-N0402-11 **2** S

10 V Screw- Batt. Disconn.Unit to Tray 140380-N0402-12 **3** S

11 V Screw- Batt. Disconn.Unit to Tray Bracket 140380-N0402-13 **1** S

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit**

**T1 or OEM Total Manufacturing Cost: $37.24**  **$0.99 $4.64**  **$42.87 $0.00**  **$0.00 $0.00** 

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

----- ----- ----- ----- 0.70% 7.00% 8.00%

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

----- ----- ----- **$0.30 $3.00**  **$3.43**

**Base Cost Impact to Vehicle: $37.24**  **$0.99 $4.64**  **$42.87 $0.30**  **$3.00 $3.43**  

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to

T1 or OEM for Final or Sub

- Assembly. In addition component material cost is

accounted for in T1 quote sheet. Thus component cost will only be included for

Mark

- up Calculations.

"Alpha

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

Supplier for Subassembly.

**Reference Packaging Database for Additonal Infromation**

Maximum Pallet Stack Height = 100"

Pallet Options

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment**

**(%) Total # of** 

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** 



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000

**Packaging**

**Cost per**

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per** 

### PACKAGING CALCULATIONS:

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers: Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification:

**System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)**  

## Annual Component Volume: Shipping Method:

**Component Description: V Battery Disconnect Unit, Traction Battery Assembly**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life:

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) 9,574** 

**10 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Series Gasoline Hybrid**

**MARK-UP COSTS** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Q uote**  **Modification Q uote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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



### Packaging Cost Total: **$0.000** 

### Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

V Battery Disconnect Unit 140303-N0402-01

V Chassis - Battery Disconn Unit 140303-N0402-02

V Stud - Positive Terminal 140303-N0402-03

V Stud - Negative Terminal 140303-N0402-04



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

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc. 

## OEM Plant Location:

Supplier Plant Location:

OEM/T1 Classification: **T1 High Assembly Complexity**



## Shipping Method:

Packaging Specification:

Production Year: **2008/2009**

**ED&T/**

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%**

**0.00% 0.00%**  **$0.00 $4.40**  **$4.40 $0.00**  **$0.73 $3.67**  **$4.40 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Final Assembly & Integration - Battery Disconnect Unit **3.5 2**  **10 70**  **47 3290**  **137 26.32**  **85%**

**0.00% 0.00%**  **$0.00 $1.14**  **$1.14 $0.39**  **$0.16 $0.59**  **$1.14 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Insert Mold two (2) terminal studs 281.92mm x 110.1mm x 63.1mm (725 ton press) **2.5 2**  **10 50**  **47 2350**  **191 18.80**  **85%**

**0.00% 0.00%**  **$0.00 $0.57**  **$0.57 $0.34**  **$0.05 $0.19**  **$0.57 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  THEO-TL-05BB, Bar Capacity=Ø51mm **3 2**  **10 60**  **47 2820**  **160 22.56**  **85%**

**0.00% 0.00%**  **$0.00 $0.52**  **$0.52 $0.28**  **$0.05 $0.19**  **$0.52 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  THEO-TL-05BB, Bar Capacity=Ø51mm **3 2**  **10 60**  **47 2820**  **160 22.56**  **85%**

**Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item** 

### North America

**North America**

**FOB Ship Point**

**Projected Operating Pattern Minimum Calculated Cycles Time**  **MARK-UP COSTS MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Process Information**  **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**TOTAL COSTS TOOLING & INVESTMENT** 

V Module - Auto Batt. Discharge 140303-N0402-06

V Screw - Battery Discharge Mod. 140380-N0402-08

V Bus Bar - Auto Discharge 140303-N0402-07

V Nut - Bus Bar Auto Discharge 140380-N0402-09

V Stud - Fusable Link 140303-N0402-08

V Fuse - Battery Disconnect Box 140303-N0402-09

V Nut Fusable link 140380-N0402-10

V Signal Module - Battery 140303-N0402-10

V Screw - Batt. Signal Module 140380-N0402-11

V Screw- Batt. Disconn.Unit to Tray 140380-N0402-12

V Screw- Batt. Disconn.Unit to Tray Bracket 140380-N0402-13 **$0.00** $28.00 **$0.00 $28.00**  **$28.00 $28.00** 

**$0.00** $0.03 **$0.00 $0.06**  **$0.06 $0.06** 

**$0.00** $0.40 **$0.00 $0.40**  **$0.40 $0.40** 

**$0.00** $0.02 **$0.00 $0.02**  **$0.02 $0.02** 

**$0.00** $0.30 **$0.00 $0.30**  **$0.30 $0.30** 

**$0.00** $0.25 **$0.00 $0.25**  **$0.25 $0.25** 

**$0.00** $0.03 **$0.00 $0.03**  **$0.03 $0.03** 

**$0.00** $7.00 **$0.00 $7.00**  **$7.00 $7.00** 

**$0.00** $0.03 **$0.00 $0.06**  **$0.06 $0.06** 

**$0.00** $0.03 **$0.00 $0.09**  **$0.09 $0.09** 

**$0.00** $0.03 **$0.00 $0.03**  **$0.03 $0.03** 

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

**Total**

**$37.24 $0.99**  **$4.64 $42.87**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**ED&T Total** 

**Mark-up $42.87**  **$42.87**

**$0.00 $0.00**  **$42.87**

4.00% 19.70%

**$1.71 $8.44** 

**$1.71 $8.44**  **$51.31 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $51.31**  **3 1**  **2**



### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error. S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**

**6 57447** 

**Other #3**

**Pads**

**Pallet/Rack**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc. 

## OEM Plant Location:

Supplier Plant Location:

OEM/T1 Classification: **T1 High Assembly Complexity**



## Shipping Method:

Packaging Specification:

Production Year: **2008/2009**

**ED&T/**

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **%** 

### North America

**North America**

**FOB Ship Point**

**Projected Operating Pattern Minimum Calculated Cycles Time**  **MARK-UP COSTS MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Process Information**  **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**TOTAL COSTS TOOLING & INVESTMENT** 

0



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

V Battery Disconnect Unit 140303-N0402-01

V Chassis - Battery Disconn Unit 140303-N0402-02

V Stud - Positive Terminal 140303-N0402-03

V Stud - Negative Terminal 140303-N0402-04



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

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**

**161 22.37**  85 4 1 22 **4.0 1.0**  **164 22.00**  4.00

**225 15.98**  28 1 2 28 **1.0 1.0**  **257 14.00**  1.00

**188 19.18**  18 1 1 18 **1.0 1.0**  **200 18.00**  0.25

**188 19.18**  18 1 1 18 **1.0 1.0**  **200 18.00**  0.25 

### Minimum Calculated Cycles Time **Project Process Requirement**

V Module - Auto Batt. Discharge 140303-N0402-06

V Screw - Battery Discharge Mod. 140380-N0402-08

V Bus Bar - Auto Discharge 140303-N0402-07

V Nut - Bus Bar Auto Discharge 140380-N0402-09

V Stud - Fusable Link 140303-N0402-08

V Fuse - Battery Disconnect Box 140303-N0402-09

V Nut Fusable link 140380-N0402-10

V Signal Module - Battery 140303-N0402-10

V Screw - Batt. Signal Module 140380-N0402-11

V Screw- Batt. Disconn.Unit to Tray 140380-N0402-12

V Screw- Batt. Disconn.Unit to Tray Bracket 140380-N0402-13



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Minimum Calculated Cycles Time **Project Process Requirement**

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 High Assembly Complexity**



## System Description: **Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)** 

## Annual Component Volume: Shipping Method:

**Component Description: V Harness-Battery Pack Assembly, Traction Battery Assembly**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier**

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** 



### A 

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

B 

## Purchase Part - High Impact Item (Full Cost Mapping)

D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item** 

### TOTAL COSTS **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Series Gasoline Hybrid** 

**MARK-UP COSTS 9,574** 

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Q uote**  **Modification Quote** 

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

1 V Screw-Batt. Disconn SW Assy 140380-N0402-14 **3** S **$0.00** $0.03 **$0.00 $0.09** 

2 V Screw - Batt. Harn. Integral PCB 140380-N0402-15 **5** S **$0.00** $0.03 **$0.00 $0.15** 

3 V Nut - Auto Discharge Unit post 140380-N0402-16 **2** S **$0.00** $0.03 **$0.00 $0.06** 

4 V Harness-Battery Pack Assembly 140303-N0402-11 **1** S **$0.00** $6.00 **$0.00 $6.00** 

5 V Harness-Battery Pack Assembly 140303-N0402-12 **1** S **$0.00** $6.00 **$0.00 $6.00** 

6 V Harness Batt. Pack Signal 140303-N0402-13 **1** 4' 6" L, 15.5mm Dia (5 connectors, 4 terminal contacts) S **$0.00** $8.50 **$0.00 $8.50** 

7 V Harness- Interface 140303-N0402-14 **1** 4' 3" L, 8mm Dia w/snap-action limit switch (C&K Components) S **$0.00** $18.00 **$0.00 $18.00** 

8 V Battery Control PCB Assembly 140303-N0402-15 **1** S **$0.00** $60.09 **$0.00 $60.09** 

9 **0 $0.00**  $0.00 **$0.00 $0.00** 

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to

T1 or OEM for Final or Sub

- Assembly. In addition component material cost is

accounted for in T1 quote sheet. Thus component cost will only be included for

Mark

- up Calculations.

"Alpha

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

Supplier for Subassembly.

29

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

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

**Mark-up $98.89** 

**T1 or OEM Total Manufacturing Cost: $98.89**  **$0.00 $0.00**  **$98.89 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$98.89**

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

----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%

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

----- ----- ----- **$0.69 $6.92**  **$7.91 $3.96**  **$19.48 3**  **1**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 High Assembly Complexity**



## System Description: **Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)** 

## Annual Component Volume: Shipping Method:

**Component Description: V Harness-Battery Pack Assembly, Traction Battery Assembly**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier**

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### TOTAL COSTS **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Series Gasoline Hybrid** 

**MARK-UP COSTS 9,574** 

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Q uote**  **Modification Quote** 

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Base Cost Impact to Vehicle: $98.89**  **$0.00 $0.00**  **$98.89 $0.69**  **$6.92 $7.91**  **$3.96 $19.48**  **$118.37 $0** 

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $118.37** 

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment**

**(%) Total # of** 

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)** 

### PACKAGING CALCULATIONS:

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers: **Reference Packaging Database for Additonal Infromation**

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)**C o** **s t** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **T o** **t a** **l N** **u m** **b e** **r o** **f P** **a l** **l e** **t s** **/ R** **a c** **k s** **R e** **q u** **i r** **e d** **N u** **m b** **e r** **o f** **P a** **r t** **s p** **e r** **P a** **l l** **e t** **/ S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging**

**Cost per**

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



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



### Packaging Cost Total: **$0.000** 

### Number of Layers: Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

**Purchase Part - High Impact Item (Full Cost Mapping)**

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

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**TOOLING & INVESTMENT** 

### Projected Operating Pattern **MANUFACTURING ASSUMPTIONS**

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

V Screw-Batt. Disconn SW Assy 140380-N0402-14

V Screw - Batt. Harn. Integral PCB 140380-N0402-15

V Nut - Auto Discharge Unit post 140380-N0402-16

V Harness-Battery Pack Assembly 140303-N0402-11

V Harness-Battery Pack Assembly 140303-N0402-12

V Harness Batt. Pack Signal 140303-N0402-13

V Harness- Interface 140303-N0402-14

V Battery Control PCB Assembly 140303-N0402-15 **$0.09 $0.09** 

**$0.15 $0.15** 

**$0.06 $0.06** 

**$6.00 $6.00** 

**$6.00 $6.00** 

**$8.50 $8.50** 

**$18.00 $18.00** 

**$60.09 $60.09** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

**$0.00 $0.00** 

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

**Total**

**$98.89 $0.00**  **$0.00 $98.89**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**$98.89 2** 



### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**TOOLING & INVESTMENT** 

### Projected Operating Pattern **MANUFACTURING ASSUMPTIONS**

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$0**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

**Purchase Part - High Impact Item (Full Cost Mapping)**

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

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** **R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s**  

### Project Process Requirement

V Screw-Batt. Disconn SW Assy 140380-N0402-14

V Screw - Batt. Harn. Integral PCB 140380-N0402-15

V Nut - Auto Discharge Unit post 140380-N0402-16

V Harness-Battery Pack Assembly 140303-N0402-11

V Harness-Battery Pack Assembly 140303-N0402-12

V Harness Batt. Pack Signal 140303-N0402-13

V Harness- Interface 140303-N0402-14

V Battery Control PCB Assembly 140303-N0402-15



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** **R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s**  

### Project Process Requirement

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 High Assembly Complexity**



## System Description: **Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)** 

## Annual Component Volume: Shipping Method:

**Component Description: V Fan - Battery Pack Cooling, Traction Battery Assembly**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** 



### A 

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

1 V Fan - Battery Pack Cooling 140305-N0402-01 **1** Assemble fan housing / fan / screws / labels T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, LC **189 4**  **1 6**  0.000 **$0.00 $29.83**  **$100.00 $600.00**  **$0.00 $0.63**  **$3.17 $3.80**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$3.80 $3.80** 

2 V Housing - Battery Fan 140306-N0402-15 **1** Wash / Paint / Bake / Cure Housing T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Plating/Coating Operator Plate/Finish, SMS, MHC **409 1**  **1 1**  0.000 **$0.00 $40.84**  **$125.00 $125.00**  **$0.00 $0.10**  **$0.31 $0.41**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.41 $0.41** 

3 V Housing - Battery Fan 140306-N0402-15 **1** Stamping, Prog. Die - 200 ton T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS **225 0.5**  **1 1**  0.795 **$0.45 $42.73**  **$42.91 $42.91**  **$0.36 $0.09**  **$0.19 $0.64**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.64 $0.64** 

4 V Fan Assy - Batt. Cooling 140305-N0402-02 **1** Assemble motor housing / blade / chassis / PCB, etc. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, LC **138 3**  **1 4**  0.000 **$0.00 $29.83**  **$100.00 $400.00**  **$0.00 $0.65**  **$2.89 $3.54**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$3.54 $3.54** 

5 V Housing - Battery Fan Motor 140306-N0402-18 **1** Stamping, Prog. Die - 200 ton T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS **514 0.5**  **1 1**  0.114 **$0.45 $42.73**  **$42.91 $42.91**  **$0.05 $0.04**  **$0.08 $0.18**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.18 $0.18** 

6 V Bushing - Brass 140390-N0402-01 **1** 0.44" Dia. X 0.153 Thk. T1 Assembly, Mark-up Applied @ Bottom. Bronze-932, Bar Lathe/Turning Operator DS-CNC Turning, SS, BF, QA **900 0.5**  **1 1**  0.004 **$2.56 $38.97**  **$37.93 $37.93**  **$0.01 $0.02**  **$0.04 $0.07**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.07 $0.07** 

7 V Shaft- Fan Motor 140380-N0402-25 **1** Turned part T1 Assembly, Mark-up Applied @ Bottom. S-Steel-304, Bar Lathe/Turning Operator DS-CNC Turning, SS, BF, QA **900 0.5**  **1 1**  0.004 **$1.65 $38.97**  **$37.93 $37.93**  **$0.01 $0.02**  **$0.04 $0.07**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.07 $0.07** 

8 V Spring - Fan Motor Shaft 140303-N0402-29 **1** Cut / Form T1 Assembly, Mark-up Applied @ Bottom. SPR-Steel, Coil Cut/Punch/Forming Operator Stamp/Form, XSS **900 0.5**  **1 1**  0.000 **$0.65 $42.73**  **$24.60 $24.60**  **$0.00 $0.02**  **$0.03 $0.05**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.05 $0.05** 

9 V Blade - Fan 140305-N0402-03 **1** Injection molded, 50 ton T1 Assembly, Mark-up Applied @ Bottom. HD Polypro Mold/Cast/Sinter Operator Inject. Mold, SS **900 0.25**  **1 1**  0.034 **$0.87 $41.48**  **$16.39 $16.39**  **$0.03 $0.01**  **$0.02 $0.06**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.06 $0.06**  

### 9,574

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Series Gasoline Hybrid**

**MARK-UP COSTS TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Quote Modification Q**  **uote** 

### Differential Quote (Quote S **um mary inclu**  **des costing for both T echnology Packages)** 

9 V Blade - Fan 140305-N0402-03 **1** Injection molded, 50 ton T1 Assembly, Mark-up Applied @ Bottom. HD Polypro Mold/Cast/Sinter Operator Inject. Mold, SS **900 0.25**  **1 1**  0.034 **$0.87 $41.48**  **$16.39 $16.39**  **$0.03 $0.01**  **$0.02 $0.06**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.06 $0.06** 

10 V Chassis - Batt. Fan 140306-N0402-20 **1** Insert mold (PBT) broached stator shaft, 100 ton T1 Assembly, Mark-up Applied @ Bottom. PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **257 1**  **1 1**  0.113 **$1.46 $41.48**  **$16.39 $16.39**  **$0.16 $0.16**  **$0.06 $0.39**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.39 $0.39** 

11 V Shaft - Motor Stator 140380-N0402-27 **1** Broached part, 1.077" L x 0.396" Dia. T1 Assembly, Mark-up Applied @ Bottom. Bronze-932, Bar Milling/Planing Operator CNC Turning, SS, BF, DA **1200 1**  **1 1**  0.000 **$2.56 $35.97**  **$20.48 $20.48**  **$0.00 $0.03**  **$0.02 $0.05**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.05 $0.05** 



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 V Clip Spring - Fan Motor Shaft 140380-N0402-26 **1** S Commodity **$0.00** $0.04 **$0.00 $0.04** 

2 V Screw - Batt. Fan to Housing 140380-N0402-29 **4** S **$0.00** $0.03 **$0.00 $0.12** 

3 V Label - Bar Code Batt. Fan 140399-N0402-06 **1** S Polyethylene **$0.00** $0.04 **$0.00 $0.04** 

4 V Label - Batt. Fan Warning 140399-N0402-07 **1** S Polyethylene **$0.00** $0.04 **$0.00 $0.04** 

5 V Bearing - Fan Motor 140390-N0402-02 **2** 0.211" OD x 0.053" H x 0.006" ID http://www.impactbearing.com/ S Commodity **$0.00** $0.02 **$0.00 $0.04** 

6 V Screw- Battery Pack Cooling Fan 140380-N0402-30 **4** S **$0.00** $0.03 **$0.00 $0.12** 

7 V PCB - Batt Fan 140303-N0402-30 **1** S **$0.00** $12.99 **$0.00 $12.99** 

8 V Seal - Batt. Fan - Case 140385-N0402-01 **2** S FOAM **$0.00** $0.07 **$0.00 $0.14** 

9 V Magnet- Fan Motor 140303-N0402-28 **1** S Plastic Molded **$0.00** $0.10 **$0.00 $0.10** 

10 V Stator Windings - Batt. Fan Assy 140303-N0402-31 **1** Molded bobbin, wound copper wire, silicon steel plates S **$0.00** $0.65 **$0.00 $0.65** 

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

**Mark-up $23.52** 

**T1 or OEM Total Manufacturing Cost: $14.90**  **$1.78 $6.85**  **$23.52 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$23.52**

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

----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%

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

----- ----- ----- **$0.16 $1.65**  **$1.88 $0.94**  **$4.63**

**Base Cost Impact to Vehicle: $14.90**  **$1.78 $6.85**  **$23.52 $0.16**  **$1.65 $1.88**  **$0.94 $4.63**  **$28.16 $0** 

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $28.16**  

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1

or OEM for Final or Sub

- Assembly. In addition component material cost is

accounted for in T1 quote sheet. Thus component cost will only be included for

Mark

- up Calculations.

"Alpha

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

Supplier for Subassembly.

**3 1** 

**Net Cost Impact to Vehicle: $28.16** 

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment**

**(%) Total # of** 

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)** 

### PACKAGING CALCULATIONS:

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers: **Reference Packaging Database for Additonal Infromation**

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 High Assembly Complexity**



## System Description: **Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)** 

## Annual Component Volume: Shipping Method:

**Component Description: V Fan - Battery Pack Cooling, Traction Battery Assembly**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### 9,574

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Series Gasoline Hybrid**

**MARK-UP COSTS TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Quote Modification Q**  **uote** 

### Differential Quote (Quote S **um mary inclu**  **des costing for both T echnology Packages)** 

**Rack/Pallet Investment Amortization: $0.000**  **$0 0.00%**  **2,250,000 60**  **5.00%** $0 **58** 1000 **6 57447** 

**Packaging**

**Cost per**

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



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



### Packaging Cost Total: **$0.000** 

### Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

V Fan - Battery Pack Cooling 140305-N0402-01

V Housing - Battery Fan 140306-N0402-15

V Housing - Battery Fan 140306-N0402-15

V Fan Assy - Batt. Cooling 140305-N0402-02

V Housing - Battery Fan Motor 140306-N0402-18

V Bushing - Brass 140390-N0402-01

V Shaft- Fan Motor 140380-N0402-25

V Spring - Fan Motor Shaft 140303-N0402-29

V Blade - Fan 140305-N0402-03 

### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **"**

**$0.00 $0.63**  **$3.17 $3.80**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Assemble fan housing / fan / screws / labels **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 96 6 1 19

**$0.00 $0.10**  **$0.31 $0.41**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Wa sh / Paint / Bake / Cure Housing **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 440 1 50 440

**$0.36 $0.09**  **$0.19 $0.64**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Stamping, Prog. Die - 200 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1 1 1 16

**$0.00 $0.65**  **$2.89 $3.54**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Assemble motor housing / blade / chassis / PCB, etc. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 95 4 1 26

**$0.05 $0.04**  **$0.08 $0.18**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Stamping, Prog. Die - 200 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 7 1 1 7

**$0.01 $0.02**  **$0.04 $0.07**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** 0.44" Dia. X 0.153 Thk. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 4 1 1 4

**$0.01 $0.02**  **$0.04 $0.07**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Turned part **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 4 1 1 4

**$0.00 $0.02**  **$0.03 $0.05**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Cut / Form **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 4 1 1 4

**$0.03 $0.01**  **$0.02 $0.06**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Inj ection molded, 50 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 8 1 2 8 

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOOLING & INVESTMENT**

V Blade - Fan 140305-N0402-03

V Chassis - Batt. Fan 140306-N0402-20

V Shaft - Motor Stator 140380-N0402-27



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

V Clip Spring - Fan Motor Shaft 140380-N0402-26

V Screw - Batt. Fan to Housing 140380-N0402-29

V Label - Bar Code Batt. Fan 140399-N0402-06

V Label - Batt. Fan Warning 140399-N0402-07

V Bearing - Fan Motor 140390-N0402-02

V Screw- Battery Pack Cooling Fan 140380-N0402-30

V PCB - Batt Fan 140303-N0402-30

V Seal - Batt. Fan - Case 140385-N0402-01

V Magnet- Fan Motor 140303-N0402-28

V Stator Windings - Batt. Fan Assy 140303-N0402-31 **$0.03 $0.01**  **$0.02 $0.06**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Inj ection molded, 50 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 8 1 2 8

**$0.16 $0.16**  **$0.06 $0.39**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Insert mold (PBT) broached stator shaft, 100 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 28 1 2 28

**$0.00 $0.03**  **$0.02 $0.05**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Broached part, 1.077" L x 0.396" Dia. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 3 1 1 3

**$0.04 $0.04** 

**$0.12 $0.12** 

**$0.04 $0.04** 

**$0.04 $0.04** 

**$0.04 $0.04** 

**$0.12 $0.12** 

**$12.99 $12.99** 

**$0.14 $0.14** 

**$0.10 $0.10** 

**$0.65 $0.65** 

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

**Total**

**$14.90 $1.78**  **$6.85 $23.52**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**$23.52**

**$0 2** 



### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **"** 

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOOLING & INVESTMENT**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

V Fan - Battery Pack Cooling 140305-N0402-01

V Housing - Battery Fan 140306-N0402-15

V Housing - Battery Fan 140306-N0402-15

V Fan Assy - Batt. Cooling 140305-N0402-02

V Housing - Battery Fan Motor 140306-N0402-18

V Bushing - Brass 140390-N0402-01

V Shaft- Fan Motor 140380-N0402-25

V Spring - Fan Motor Shaft 140303-N0402-29

V Blade - Fan 140305-N0402-03 

### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**

**6.0 1.0**  **189 19.00**  4.00

**1.0 1.0**  **409 8.80**  1.00

**1.0 1.0**  **225 16.00**  0.50

**4.0 1.0**  **138 26.00**  3.00

**1.0 1.0**  **514 7.00**  0.50

**1.0 1.0**  **900 4.00**  0.50

**1.0 1.0**  **900 4.00**  0.50

**1.0 1.0**  **900 4.00**  0.50

**1.0 1.0**  **900 4.00**  0.25 

### Project Process Requirement

V Blade - Fan 140305-N0402-03

V Chassis - Batt. Fan 140306-N0402-20

V Shaft - Motor Stator 140380-N0402-27



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

V Clip Spring - Fan Motor Shaft 140380-N0402-26

V Screw - Batt. Fan to Housing 140380-N0402-29

V Label - Bar Code Batt. Fan 140399-N0402-06

V Label - Batt. Fan Warning 140399-N0402-07

V Bearing - Fan Motor 140390-N0402-02

V Screw- Battery Pack Cooling Fan 140380-N0402-30

V PCB - Batt Fan 140303-N0402-30

V Seal - Batt. Fan - Case 140385-N0402-01

V Magnet- Fan Motor 140303-N0402-28

V Stator Windings - Batt. Fan Assy 140303-N0402-31 **1.0 1.0**  **900 4.00**  0.25

**1.0 1.0**  **257 14.00**  1.00

**1.0 1.0**  **1200 3.00**  1.00



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Project Process Requirement

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year):

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV):

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine:

**System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)**  

## Annual Component Volume:

**Component Description: V PCB - Batt Fan**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume:

**Component Quote Level:** Estimated Product Life:

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB)**

A 

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

1 V PCB - Batt Fan-Functional Test 140303-N0402-30 **1** Functional Test, Low Content Boards with 0-160 Chips/side and a Max of 70 odd form components. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly EOL Func.Test, Low Content **180 1**  **1 1**  0.000 **$0.00 $29.83**  **$14.09 $14.09**  **$0.00 $0.17**  **$0.08 $0.24**  **0.00%**

2 V PCB - Batt Fan-Depannel 140303-N0402-30 **1** De-Panel-Blade Station, In-line, Simple Straight cut geometries, robust boards (i.e., large traces) and solder joints. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly De-Panel, In-Line, Blade **450 1**  **1 1**  0.000 **$0.00 $29.83**  **$8.79 $8.79**  **$0.00 $0.07**  **$0.02 $0.09**  **0.00%**

3 V PCB - Batt Fan-Conformal Coat 140303-N0402-30 **1** PVA Coating Applicator T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Conformal Coat, UV Cure **720 1**  **1 2**  0.000 **$0.00 $29.83**  **$28.33 $56.66**  **$0.00 $0.04**  **$0.08 $0.12**  **0.00%**

4 V PCB - Batt Fan-Thru Hole 140303-N0402-30 **1** Thru Hole Chip Placement Assembly Line, 1-Automated and 1 Manual workstation, Max 9 chips per side with automated

equipment. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Thru Hole, Auto **124 1**  **1 2**  0.000 **$0.00 $29.83**  **$62.59 $125.18**  **$0.00 $0.24**  **$1.01 $1.25**  **0.00%**

5 BOTTOM SIDE - SURFACE MOUNT 140303-N0402-30 **1** DEK Screen Printer T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly SMT, Low Content **450 0.5**  **1 1**  0.000 **$0.00 $29.83**  **$212.63 $212.63**  **$0.00 $0.03**  **$0.47 $0.51**  **0.00%**

6 TOP SIDE - SURFACE MOUNT 140303-N0402-30 **1** DEK Screen Printer T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly SMT, Low Content **450 0.5**  **1 1**  0.000 **$0.00 $29.83**  **$212.63 $212.63**  **$0.00 $0.03**  **$0.47 $0.51**  **0.00%**



### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Series Gasoline Hybrid** 

**9,574**

**10 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Q uote**  **Modification Q uote**  

### Di **ffe ren**  **tial Quote (Quote S um**  **mary in clu**  **des costing for both T echnology Packages)** 



### D 

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

1 V PCB - Batt Fan-SMT - Bare Commodity Price **1** S

2 IC - Voltage Regulator UA78L05ACDRE 4-ND **1** S

3 IC - Transciever SN65MLVD200D **1** S

4 Transistor - Surface Mount BC848C-TPMSCT-ND **7** S

5 Zener Diode - Surface Mount DL5244B-TPMSCT-ND **1** S

6 IC IC fan control bpard **1** S

7 Capacitors Capacitors-1 **3** S

8 Resistors Resistors-1 **27** S

9 MOSFETs - Surface Mount SP8M8TBCT-ND **2** S

10 IC PIC16F684 **1** S

11 Fuse - Surface Mount F2933CT-ND **1** S

12 Diode - Schottky - Surface Mount B340A-FDITR-ND **3** S

13 Transistor - Surface Mount BC848C-TPMSCT-ND **1** S

14 Zener Diode - Surface Mount DL5244B-TPMSCT-ND **1** S

15 Diode - Schottky - Surface Mount SS3P3-E3/84AGICT-ND **1** S

16 Capacitor - Surface Mount P930-ND **1** S

17 Capacitors Capacitors-1 **5** S

18 Resistors Resistors-1 **7** S

19 4 pin connector Commodity Price **1** S

**Material Labor**  **Burden TMC**  **Scrap** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly

to T1 or OEM for Final or Sub

- Assembly. In addition component material cost

is accounted for in T1 quote sheet. Thus component cost will only be included

for Mark

- up Calculations.

**T1 or OEM Total Manufacturing Cost: $8.14**  **$0.58 $2.13**  **$10.85 $0.00** 

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

----- ----- ----- ----- 0.70%

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

----- ----- ----- **$0.08**

**Base Cost Impact to Vehicle: $8.14**  **$0.58 $2.13**  **$10.85 $0.08** 



### Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year):

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV):

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine:

**System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)**  

## Annual Component Volume:

**Component Description: V PCB - Batt Fan**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume:

**Component Quote Level:** Estimated Product Life:

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) GENERAL COMPONENT INFORMATION**  **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Series Gasoline Hybrid** 

**9,574**

**10 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Q uote**  **Modification Q uote**  

### Di **ffe ren**  **tial Quote (Quote S um**  **mary in clu**  **des costing for both T echnology Packages)** 

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment**

**(%) Total # of** 

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0

**Packaging**

**Cost per**

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per**



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

### PACKAGING CALCULATIONS:

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers: Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base **Expendable Packaging in Piece Cost: $0.00**  $0.00 0 $0.00 0 $0.00 0 $0.00



### Packaging Cost Total: **$0.000** 

### Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

V PCB - Batt Fan-Functional Test 140303-N0402-30

V PCB - Batt Fan-Depannel 140303-N0402-30

V PCB - Batt Fan-Conformal Coat 140303-N0402-30

V PCB - Batt Fan-Thru Hole 140303-N0402-30

BOTTOM SIDE - SURFACE MOUNT 140303-N0402-30

TOP SIDE - SURFACE MOUNT 140303-N0402-30



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc. 

## OEM Plant Location:

Supplier Plant Location:

OEM/T1 Classification: **T1 High Assembly Complexity**



## Shipping Method:

Packaging Specification:

Production Year: **2008/2009**

**SG&A**

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr.**

**0.00% 0.00%**  **0.00% 0.00%**  **$0.00 $0.24**  **$0.24 $0.00**  **$0.17 $0.08**  **$0.24 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Functional Test, Low Content Boards with 0-160 Chips/side and a Max of 70 odd

form components. **5 2**  **10 100**  **47**

**0.00% 0.00%**  **0.00% 0.00%**  **$0.00 $0.09**  **$0.09 $0.00**  **$0.07 $0.02**  **$0.09 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  De-Panel-Blade Station, In-line, Simple Straight cut geometries, robust boards

(i.e., large traces) and solder joints. **5 2**  **10 100**  **47**

**0.00% 0.00%**  **0.00% 0.00%**  **$0.00 $0.12**  **$0.12 $0.00**  **$0.04 $0.08**  **$0.12 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  PVA Coating Applicator **5 2**  **10 100**  **47**

**0.00% 0.00%**  **0.00% 0.00%**  **$0.00 $1.25**  **$1.25 $0.00**  **$0.24 $1.01**  **$1.25 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Thru Hole Chip Placement Assembly Line, 1-Automated and 1 Manual

workstation, Max 9 chips per side with automated equipment. **5 2**  **10 100**  **47**

**0.00% 0.00%**  **0.00% 0.00%**  **$0.00 $0.51**  **$0.51 $0.00**  **$0.03 $0.47**  **$0.51 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  DEK Screen Printer **5 2**  **10 100**  **47**

**0.00% 0.00%**  **0.00% 0.00%**  **$0.00 $0.51**  **$0.51 $0.00**  **$0.03 $0.47**  **$0.51 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  DEK Screen Printer **5 2**  **10 100**  **47** 

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**TOTAL COSTS TOOLING & INVESTMENT**  

### Projected Operating Pattern **MARK-UP COSTS MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity North America** 

**North America**

**FOB Ship Point**



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

V PCB - Batt Fan-SMT - Bare Commodity Price

IC - Voltage Regulator UA78L05ACDRE 4-ND

IC - Transciever SN65MLVD200D

Transistor - Surface Mount BC848C-TPMSCT-ND

Zener Diode - Surface Mount DL5244B-TPMSCT-ND

IC IC fan control bpard

Capacitors Capacitors-1

Resistors Resistors-1

MOSFETs - Surface Mount SP8M8TBCT-ND

IC PIC16F684

Fuse - Surface Mount F2933CT-ND

Diode - Schottky - Surface Mount B340A-FDITR-ND

Transistor - Surface Mount BC848C-TPMSCT-ND

Zener Diode - Surface Mount DL5244B-TPMSCT-ND

Diode - Schottky - Surface Mount SS3P3-E3/84AGICT-ND

Capacitor - Surface Mount P930-ND

Capacitors Capacitors-1

Resistors Resistors-1

4 pin connector Commodity Price **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

**$0.00** $0.34 **$0.00 $0.34**  **$0.34 $0.34** 

**$0.00** $1.17 **$0.00 $1.17**  **$1.17 $1.17** 

**$0.00** $1.72 **$0.00 $1.72**  **$1.72 $1.72** 

**$0.00** $0.07 **$0.00 $0.49**  **$0.49 $0.49** 

**$0.00** $0.07 **$0.00 $0.07**  **$0.07 $0.07** 

**$0.00** $0.50 **$0.00 $0.50**  **$0.50 $0.50** 

**$0.00** $0.01 **$0.00 $0.03**  **$0.03 $0.03** 

**$0.00** $0.01 **$0.00 $0.27**  **$0.27 $0.27** 

**$0.00** $0.32 **$0.00 $0.64**  **$0.64 $0.64** 

**$0.00** $0.75 **$0.00 $0.75**  **$0.75 $0.75** 

**$0.00** $0.86 **$0.00 $0.86**  **$0.86 $0.86** 

**$0.00** $0.19 **$0.00 $0.57**  **$0.57 $0.57** 

**$0.00** $0.07 **$0.00 $0.07**  **$0.07 $0.07** 

**$0.00** $0.07 **$0.00 $0.07**  **$0.07 $0.07** 

**$0.00** $0.14 **$0.00 $0.14**  **$0.14 $0.14** 

**$0.00** $0.03 **$0.00 $0.03**  **$0.03 $0.03** 

**$0.00** $0.01 **$0.00 $0.05**  **$0.05 $0.05** 

**$0.00** $0.01 **$0.00 $0.07**  **$0.07 $0.07** 

**$0.00** $0.30 **$0.00 $0.30**  **$0.30 $0.30** 

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

**Total**

**$8.14 $0.58**  **$2.13 $10.85**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**SG&A Profit**  **ED&T Total** 

**Mark-up $10.85**  **$10.85 1**  **2**

**$0.00 $0.00**  **$0.00 $0.00**  **$10.85**

7.00% 8.00% 4.00% 19.70%

**$0.76 $0.87**  **$0.43 $2.14** 

**$0.76 $0.87**  **$0.43 $2.14**  **$12.99 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $12.99**  **3** 

### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc. 

## OEM Plant Location:

Supplier Plant Location:

OEM/T1 Classification: **T1 High Assembly Complexity**



## Shipping Method:

Packaging Specification:

Production Year: **2008/2009**

**SG&A**

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Process Information**  **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**TOTAL COSTS TOOLING & INVESTMENT**  

### Projected Operating Pattern **MARK-UP COSTS MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity North America** 

**North America**

**FOB Ship Point T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**

**58** 1000 **6 57447** 

**Other #2**

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**

0 $0.00 0



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

V PCB - Batt Fan-Functional Test 140303-N0402-30

V PCB - Batt Fan-Depannel 140303-N0402-30

V PCB - Batt Fan-Conformal Coat 140303-N0402-30

V PCB - Batt Fan-Thru Hole 140303-N0402-30

BOTTOM SIDE - SURFACE MOUNT 140303-N0402-30

TOP SIDE - SURFACE MOUNT 140303-N0402-30



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Hrs./

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** **R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**4700 96**  **37.60 85%**  **113 31.96**  20 1 1 20 **1.0 1.0**  **180 20.00**  1.00

**4700 96**  **37.60 85%**  **113 31.96**  8 1 1 8 **1.0 1.0**  **450 8.00**  1.00

**4700 96**  **37.60 85%**  **113 31.96**  10 2 1 5 **2.0 1.0**  **720 5.00**  1.00

**4700 96**  **37.60 85%**  **113 31.96**  49 2 1 29 **2.0 1.0**  **124 29.00**  1.00

**4700 96**  **37.60 85%**  **113 31.96**  8 1 1 8 **1.0 1.0**  **450 8.00**  0.50

**4700 96**  **37.60 85%**  **113 31.96**  8 1 1 8 **1.0 1.0**  **450 8.00**  0.50 

### MANUFACTURING ASSUMPTIONS

**Project Process Requirement Minimum Calculated Cycles Time** 



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

V PCB - Batt Fan-SMT - Bare Commodity Price

IC - Voltage Regulator UA78L05ACDRE 4-ND

IC - Transciever SN65MLVD200D

Transistor - Surface Mount BC848C-TPMSCT-ND

Zener Diode - Surface Mount DL5244B-TPMSCT-ND

IC IC fan control bpard

Capacitors Capacitors-1

Resistors Resistors-1

MOSFETs - Surface Mount SP8M8TBCT-ND

IC PIC16F684

Fuse - Surface Mount F2933CT-ND

Diode - Schottky - Surface Mount B340A-FDITR-ND

Transistor - Surface Mount BC848C-TPMSCT-ND

Zener Diode - Surface Mount DL5244B-TPMSCT-ND

Diode - Schottky - Surface Mount SS3P3-E3/84AGICT-ND

Capacitor - Surface Mount P930-ND

Capacitors Capacitors-1

Resistors Resistors-1

4 pin connector Commodity Price



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Hrs./

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** **R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s**  

### MANUFACTURING ASSUMPTIONS

**Project Process Requirement Minimum Calculated Cycles Time** 

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 High Assembly Complexity**



## System Description: **Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)** 

## Annual Component Volume: Shipping Method:

**Component Description: V Battery Pack Lid, Traction Battery Assembly**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier**

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** 



### A 

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

B 

## Purchase Part - High Impact Item (Full Cost Mapping)

1 V Battery Pack Lid Assembly 140306-N0402-11 **1** Assemble Lid / Fasteners / Labels T2/T3 Elect. Assembly, SSLC Not Applicable Electrical Assembly Elec. Assembly, LC **120 2**  **1 3**  0.000 **$0.00 $29.83**  **$100.00 $300.00**  **$0.00 $0.50**  **$2.50 $3.00**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.31**  **$3.31 $3.31** 

2 V Battery Pack Lid Weldment 140306-N0402-12 **1** Wash / Paint / Bake / Cure T2/T3 Plate/Finish Elect., SSLC Not Applicable Plating/Coating Operator Plate/Finish, SMS, MHC **244 1**  **1 1**  0.000 **$0.00 $40.84**  **$125.00 $125.00**  **$0.00 $0.17**  **$0.51 $0.68**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.07**  **$0.75 $0.75** 

3 V Battery Pack Lid Weldment 140306-N0402-12 **1** Weld, Projection - Bracket to Nut (12) T2/T3 Mech. Assembly, SSLC Not Applicable Welding/Soldering Operator Mech. Assembly, LC **720 1**  **1 1**  0.000 **$0.00 $41.55**  **$100.00 $100.00**  **$0.00 $0.06**  **$0.14 $0.20**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.22 $0.22** 

4 V Battery Pack Lid Stamping 140306-N0402-13 **1** Drill one (1) 30mm hole T2/T3 CNC Milling, SSLC Not Applicable Drilling/Boring Operator Dedicated Machining Center - Single Station, LC, Base **257 1**  **1 1**  0.000 **$0.00 $38.69**  **$30.38 $30.38**  **$0.00 $0.15**  **$0.12 $0.27**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.30 $0.30** 

5 V Battery Pack Lid Stamping 140306-N0402-13 **1** Stamping, Prog. Die - 1000 ton T2/T3 Stamp/Form, LSHC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, LS **189 0.5**  **1 1**  7.884 **$0.45 $42.73**  **$141.76 $141.76**  **$3.55 $0.11**  **$0.75 $4.41**  **0.70% 7.00%**  **8.00% 2.00%**  **17.70% $0.78**  **$5.19 $5.19**  

### TOTAL COSTS **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Series Gasoline Hybrid** 

**MARK-UP COSTS 9,574** 

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Q uote**  **Modification Q uote**  

### Di **ffe ren**  **tial Quote (Quote S um**  **mary in clu**  **des costing for both T echnology Packages)** 



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database ) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 v Weld Nut - Projection 140380-N0402-21 **4** S **$0.00** $0.04 **$0.00 $0.16** 

2 V Weld Nut - Projection Large 140380-N0402-22 **1** S **$0.00** $0.05 **$0.00 $0.05** 

3 V Velcro Patch 140399-N0402-02 **3** Velcro S **$0.00** $0.07 **$0.00 $0.21** 

4 V Label - 36V Caution 140399-N0402-03 **1** Polyethylene S **$0.00** $0.04 **$0.00 $0.04** 

5 V Label - Bar Code 140399-N0402-04 **1** Polyethylene S **$0.00** $0.04 **$0.00 $0.04** 

6 v Label - NiMH Recycle 140399-N0402-05 **1** Polyethylene S **$0.00** $0.04 **$0.00 $0.04** 

7 V Clip - Rosebud WH 140380-N0402-23 **1** Polypropylene S **$0.00** $0.05 **$0.00 $0.05** 

8 V Screw - Battery Pack Lid 140380-N0402-24 **12** S **$0.00** $0.03 **$0.00 $0.36** 

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

**Mark-up $10.71** 

**T1 or OEM Total Manufacturing Cost: $4.50**  **$0.99 $4.02**  **$9.50 $0.04**  **$0.56 $0.52**  **$0.09 $1.21**  **$10.71**

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

----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%

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

----- ----- ----- **$0.07 $0.75**  **$0.86 $0.43**  **$2.11**

**Base Cost Impact to Vehicle: $4.50**  **$0.99 $4.02**  **$9.50 $0.12**  **$1.31 $1.38**  **$0.52 $3.32**  **$12.82 $0** 

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $12.82** **N u** **m b** **e r** **o f** **P a** **r t** **s p** **e r** **P a** **l l** **e t** **/ S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** **** 

### PACKAGING CALCULATIONS: "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

- Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for

Final or Sub

- Assembly. In addition component material cost is accounted for in T1 quote sheet.

Thus component cost will only be included for Mark

- up Calculations.

"Alpha

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

Subassembly.

**3 1** 



### Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment**

**(%) Total # of** 

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging**

**Cost per**

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack** 

### PACKAGING CALCULATIONS:

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers: Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 High Assembly Complexity**



## System Description: **Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)** 

## Annual Component Volume: Shipping Method:

**Component Description: V Battery Pack Lid, Traction Battery Assembly**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier**

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### TOTAL COSTS **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Series Gasoline Hybrid** 

**MARK-UP COSTS 9,574** 

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Q uote**  **Modification Q uote**  

### Di **ffe ren**  **tial Quote (Quote S um**  **mary in clu**  **des costing for both T echnology Packages)** 

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



### Packaging Cost Total: **$0.000** 

### Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

**Purchase Part - High Impact Item (Full Cost Mapping)**

V Battery Pack Lid Assembly 140306-N0402-11

V Battery Pack Lid Weldment 140306-N0402-12

V Battery Pack Lid Weldment 140306-N0402-12

V Battery Pack Lid Stamping 140306-N0402-13

V Battery Pack Lid Stamping 140306-N0402-13



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** 

**$0.00 $0.50**  **$2.50 $3.00**  **$0.01 $0.18**  **$0.12 $0.00**  **$0.31** Assemble Lid / Fasteners / Labels **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 81 3 1

**$0.00 $0.17**  **$0.51 $0.68**  **$0.00 $0.04**  **$0.03 $0.00**  **$0.07** Wa sh / Paint / Bake / Cure **3 2**  **10 60**  **47 2820**  **160 22.56**  **85% 188**  **19.18** 443 1 30

**$0.00 $0.06**  **$0.14 $0.20**  **$0.00 $0.01**  **$0.01 $0.00**  **$0.02** We ld, Projection - Bracket to Nut (12) **1 2**  **10 20**  **47 940**  **479 7.52**  **85% 563**  **6.39** 5 1 1

**$0.00 $0.15**  **$0.12 $0.27**  **$0.00 $0.02**  **$0.01 $0.00**  **$0.03** Drill one (1) 30mm hole **2.5 2**  **10 50**  **47 2350**  **191 18.80**  **85% 225**  **15.98** 14 1 1

**$3.55 $0.11**  **$0.75 $4.41**  **$0.03 $0.31**  **$0.35 $0.09**  **$0.78** Stamping, Prog. Die - 1000 ton **3 2**  **10 60**  **47 2820**  **160 22.56**  **85% 188**  **19.18** 19 1 1 

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**TOOLING & INVESTMENT** 

### Projected Operating Pattern **MANUFACTURING ASSUMPTIONS**

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**



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

v Weld Nut - Projection 140380-N0402-21

V Weld Nut - Projection Large 140380-N0402-22

V Velcro Patch 140399-N0402-02

V Label - 36V Caution 140399-N0402-03

V Label - Bar Code 140399-N0402-04

v Label - NiMH Recycle 140399-N0402-05

V Clip - Rosebud WH 140380-N0402-23

V Screw - Battery Pack Lid 140380-N0402-24 **$0.16 $0.16** 

**$0.05 $0.05** 

**$0.21 $0.21** 

**$0.04 $0.04** 

**$0.04 $0.04** 

**$0.04 $0.04** 

**$0.05 $0.05** 

**$0.36 $0.36** 

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

**Total**

**$4.50 $0.99**  **$4.02 $9.50**  **$0.04 $0.56**  **$0.52 $0.09**  **$1.21**

**$10.71**

**$0 2** 



### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**TOOLING & INVESTMENT** 

### Projected Operating Pattern **MANUFACTURING ASSUMPTIONS**

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

**Purchase Part - High Impact Item (Full Cost Mapping)**

V Battery Pack Lid Assembly 140306-N0402-11

V Battery Pack Lid Weldment 140306-N0402-12

V Battery Pack Lid Weldment 140306-N0402-12

V Battery Pack Lid Stamping 140306-N0402-13

V Battery Pack Lid Stamping 140306-N0402-13



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** **R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

30 **3.0 1.0**  **120 30.00**  2.00

443 **1.0 1.0**  **244 14.77**  1.00

5 **1.0 1.0**  **720 5.00**  1.00

14 **1.0 1.0**  **257 14.00**  1.00

19 **1.0 1.0**  **189 19.00**  0.50 

### Project Process Requirement



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

v Weld Nut - Projection 140380-N0402-21

V Weld Nut - Projection Large 140380-N0402-22

V Velcro Patch 140399-N0402-02

V Label - 36V Caution 140399-N0402-03

V Label - Bar Code 140399-N0402-04

v Label - NiMH Recycle 140399-N0402-05

V Clip - Rosebud WH 140380-N0402-23

V Screw - Battery Pack Lid 140380-N0402-24



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** **R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### Project Process Requirement

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 high Assembly Complexity**



## System Description: **Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)** 

## Annual Component Volume: Shipping Method:

**Component Description: V Fan - Battery Pack Cooling, Traction Battery Assembly**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** 



### A 

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

B 

## Purchase Part - High Impact Item (Full Cost Mapping)

1 V Battery Pack Service Door Weldment 140306-N0402-23 **1** Wash / Paint / Bake / Cure Service Door Weldment T2/T3 Plate/Finish Elect., SSLC Not Applicable Plating/Coating Operator Plate/Finish, SMS, MHC **245 1**  **1 1**  0.000 **$0.00 $40.84**  **$125.00 $125.00**  **$0.00 $0.17**  **$0.51 $0.68**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.07**  **$0.75 $0.75** 

2 V Battery Pack Service Door Weldment 140306-N0402-23 **1** Weld, Spot - Hinges, Service Door Stamping, Pins T2/T3 Mech. Assembly, SSLC Not Applicable Welding/Soldering Operator Mech. Assembly, LC **129 1**  **1 1**  0.000 **$0.00 $41.55**  **$100.00 $100.00**  **$0.00 $0.32**  **$0.78 $1.10**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.11**  **$1.21 $1.21** 

3 V Battery Pack Service Door Stamping 140306-N0402-23 **1** Stamping, Prog. Die - 1000 ton T2/T3 Stamp/Form, LSHC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, LS **720 0.5**  **1 1**  1.100 **$0.45 $42.73**  **$141.76 $141.76**  **$0.50 $0.03**  **$0.20 $0.72**  **0.70% 7.00%**  **8.00% 2.00%**  **17.70% $0.13**  **$0.85 $0.85** 

4 V Battery Pack Service Door Hinge Bracket 140306-N0402-23 **2** Stamping, Prog. Die - 25 ton T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **720 0.5**  **1 1**  0.076 **$0.45 $42.73**  **$15.50 $15.50**  **$0.03 $0.03**  **$0.02 $0.09**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.09 $0.19** 

5 V Battery Pack Service Door Hinge Pins 140306-N0402-23 **2** Stamping, Prog. Die - 25 ton T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **720 0.5**  **1 1**  0.051 **$0.45 $42.73**  **$15.50 $15.50**  **$0.02 $0.03**  **$0.02 $0.07**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.08 $0.16**  

### TOTAL COSTS **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Series Gasoline Hybrid** 

**MARK-UP COSTS 9,574** 

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Quote Modification Q**  **uote** 

### Differential Quote (Quote S **um mary inclu**  **des costing for both T echnology Packages)** 



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 V Screw Battery Pack Service Door 140380-N0402-31 **1** S **$0.00** $0.03 **$0.00 $0.03** 

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

3 **0 $0.00**  $0.00 **$0.00 $0.00** 

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

**Mark-up $3.19** 

**T1 or OEM Total Manufacturing Cost: $0.64**  **$0.64 $1.57**  **$2.85 $0.01**  **$0.18 $0.14**  **$0.01 $0.34**  **$3.19**

**T1 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**  **$0.26 $0.13**  **$0.63**

**Base Cost Impact to Vehicle: $0.64**  **$0.64 $1.57**  **$2.85 $0.03**  **$0.40 $0.40**  **$0.14 $0.97**  **$3.82 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $3.82** 

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment**

**(%) Total # of** 

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)** 

### PACKAGING CALCULATIONS:

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers: "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

**3 1** 



### Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool**C o** **s t** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **T o** **t a** **l N** **u m** **b e** **r o** **f P** **a l** **l e** **t s** **/ N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging**

**Cost per**

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



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



### Packaging Cost Total: **$0.000** 

### Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 high Assembly Complexity**



## System Description: **Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)** 

## Annual Component Volume: Shipping Method:

**Component Description: V Fan - Battery Pack Cooling, Traction Battery Assembly**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### TOTAL COSTS **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Series Gasoline Hybrid** 

**MARK-UP COSTS 9,574** 

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Quote Modification Q**  **uote** 

### Differential Quote (Quote S **um mary inclu**  **des costing for both T echnology Packages)** 



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

**Purchase Part - High Impact Item (Full Cost Mapping)**

V Battery Pack Service Door Weldment 140306-N0402-23

V Battery Pack Service Door Weldment 140306-N0402-23

V Battery Pack Service Door Stamping 140306-N0402-23

V Battery Pack Service Door Hinge Bracket 140306-N0402-23

V Battery Pack Service Door Hinge Pins 140306-N0402-23 

### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** 

**$0.00 $0.17**  **$0.51 $0.68**  **$0.00 $0.04**  **$0.03 $0.00**  **$0.07** Wa sh / Paint / Bake / Cure Service Door W eldment **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 440 1 30 440 **1.0**

**$0.00 $0.32**  **$0.78 $1.10**  **$0.00 $0.07**  **$0.04 $0.00**  **$0.11** We ld, Spot - Hinges, Service Door Stamping, Pins **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 28 1 1 28 **1.0**

**$0.50 $0.03**  **$0.20 $0.72**  **$0.01 $0.05**  **$0.06 $0.01**  **$0.13** Stamping, Prog. Die - 1000 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 5 1 1 5 **1.0**

**$0.07 $0.06**  **$0.04 $0.17**  **$0.00 $0.01**  **$0.01 $0.00**  **$0.02** Stamping, Prog. Die - 25 ton **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  **15.98** 5 1 1 5 **1.0**

**$0.05 $0.06**  **$0.04 $0.15**  **$0.00 $0.01**  **$0.01 $0.00**  **$0.02** Stamping, Prog. Die - 25 ton **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  **15.98** 5 1 1 5 **1.0** 

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**



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

V Screw Battery Pack Service Door 140380-N0402-31 **$0.03 $0.03** 

**$0.00 $0.00** 

**$0.00 $0.00** 

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

**Total**

**$0.64 $0.64**  **$1.57 $2.85**  **$0.01 $0.18**  **$0.14 $0.01**  **$0.34**

**$3.19 2** 



### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

**Purchase Part - High Impact Item (Full Cost Mapping)**

V Battery Pack Service Door Weldment 140306-N0402-23

V Battery Pack Service Door Weldment 140306-N0402-23

V Battery Pack Service Door Stamping 140306-N0402-23

V Battery Pack Service Door Hinge Bracket 140306-N0402-23

V Battery Pack Service Door Hinge Pins 140306-N0402-23 

### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** **R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**1.0 245**  **14.67** 1.00

**1.0 129**  **28.00** 1.00

**1.0 720**  **5.00** 0.50

**1.0 720**  **5.00** 0.50

**1.0 720**  **5.00** 0.50 

### Project Process Requirement



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

V Screw Battery Pack Service Door 140380-N0402-31



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** **R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s**  

### Project Process Requirement

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 High Assembly Complexity**



## System Description: **Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)** 

## Annual Component Volume: Shipping Method:

**Component Description: V Tray - Battery, Traction Battery Assembly**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier**

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** 



### A 

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

B 

## Purchase Part - High Impact Item (Full Cost Mapping)

1 V Tray - Battery Assembly - Final w/Clip 140375-N0402-01 **1** Final Assembly - Snap on Rosebud Clip T2/T3 Mech. Assembly, SSLC Not Applicable Electrical Assembly Mech. Assembly, LC **1200 1**  **1 1**  0.000 **$0.00 $29.83**  **$100.00 $100.00**  **$0.00 $0.02**  **$0.08 $0.11**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.12 $0.12** 

2 V Tray - Battery Assembly - W ash & Paint 140375-N0402-01 **1** Wash / Paint / Bake / Cure Final Weldment T2/T3 Plate/Finish Elect., SSLC Not Applicable Plating/Coating Operator Plate/Finish, SMS, MHC **244 1**  **1 1**  0.000 **$0.00 $40.84**  **$125.00 $125.00**  **$0.00 $0.17**  **$0.51 $0.68**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.07**  **$0.75 $0.75** 

3 V Tray - Battery Assembly - Final W eldment 140375-N0402-01 **1** Weld, Spot - Tray & Brackets #1 thru #6 T2/T3 Mech. Assembly, SSLC Not Applicable Welding/Soldering Operator Mech. Assembly, LC **133 1**  **1 1**  0.000 **$0.00 $41.55**  **$100.00 $100.00**  **$0.00 $0.31**  **$0.75 $1.06**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.11**  **$1.17 $1.17** 

4 V Tray - Battery W eldment 140375-N0402-02 **1** Weld, Projection - Bracket to Nut (12) T2/T3 Mech. Assembly, SSLC Not Applicable Welding/Soldering Operator Mech. Assembly, LC **150 2**  **1 3**  0.000 **$0.00 $41.55**  **$100.00 $300.00**  **$0.00 $0.55**  **$2.00 $2.55**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.26**  **$2.82 $2.82** 

5 V Tray - Battery Stamping 140375-N0402-03 **1** Stamping, Prog. Die - 2000 ton T2/T3 Stamp/Form, LSHC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, 2XLS **257 0.5**  **1 1**  5.145 **$0.45 $42.73**  **$281.92 $281.92**  **$2.32 $0.08**  **$1.10 $3.49**  **0.70% 7.00%**  **8.00% 2.00%**  **17.70% $0.62**  **$4.11 $4.11** 

6 V Bracket # 1 - Batt. Tray Stamping 140375-N0402-05 **1** Stamping, Prog. Die - 2 ton T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **3600 0.5**  **1 1**  0.238 **$0.45 $42.73**  **$15.50 $15.50**  **$0.11 $0.01**  **$0.00 $0.12**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.13 $0.13**  

### 9,574

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Series Gasoline Hybrid**

**MARK-UP COSTS TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Q uote**  **Modification Q uote**  

### Di **ffe ren**  **tial Quote (Quote S um**  **mary in clu**  **des costing for both T echnology Packages)** 

6 V Bracket # 1 - Batt. Tray Stamping 140375-N0402-05 **1** Stamping, Prog. Die - 2 ton T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **3600 0.5**  **1 1**  0.238 **$0.45 $42.73**  **$15.50 $15.50**  **$0.11 $0.01**  **$0.00 $0.12**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.13 $0.13** 

7 V Bracket #2 - Battery Tray W eldment 140375-N0402-07 **1** Weld, Spot - Bracket, Access Door, Stud, etc. T2/T3 Mech. Assembly, SSLC Not Applicable Welding/Soldering Operator Mech. Assembly, LC **150 2**  **1 2**  0.000 **$0.00 $41.55**  **$100.00 $200.00**  **$0.00 $0.55**  **$1.33 $1.89**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.19**  **$2.08 $2.08** 

8 V Bracket #2 - Battery Tray Stamping 140375-N0402-09 **1** Stamping, Prog. Die - 1000 ton T2/T3 Stamp/Form, LSHC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, LS **360 0.5**  **1 1**  0.994 **$0.45 $42.73**  **$141.76 $141.76**  **$0.45 $0.06**  **$0.39 $0.90**  **0.70% 7.00%**  **8.00% 2.00%**  **17.70% $0.16**  **$1.06 $1.06** 

9 V Hinge Bracket - Access Door, Brkt #2 140375-N0402-10 **2** Stamping, Prog. Die - 25 ton T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **3600 0.5**  **1 1**  0.076 **$0.45 $42.73**  **$15.50 $15.50**  **$0.03 $0.01**  **$0.00 $0.04**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.05 $0.10** 

10 V Bracket - W eld Stud, Brkt #2 140375-N0402-12 **1** Stamping, Prog. Die - 5 ton T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **3600 1**  **1 1**  0.066 **$0.45 $42.73**  **$15.50 $15.50**  **$0.03 $0.01**  **$0.00 $0.05**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.05 $0.05** 

11 V Bracket #3 - Battery Tray W eldment 140375-N0402-14 **1** Weld, Spot - Bracket, Stand Off, Stud, etc. T2/T3 Mech. Assembly, SSLC Not Applicable Welding/Soldering Operator Mech. Assembly, LC **257 2**  **1 2**  0.000 **$0.00 $41.55**  **$100.00 $200.00**  **$0.00 $0.32**  **$0.78 $1.10**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.11**  **$1.21 $1.21** 

12 V Bracket #3 - Battery Tray Stamping 140375-N0402-15 **1** Stamping, Prog. Die - 200 ton T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS **1800 0.5**  **1 1**  0.721 **$0.45 $42.73**  **$42.91 $42.91**  **$0.32 $0.01**  **$0.02 $0.36**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.40 $0.40** 

13 V Bracket - Stand Off, Brkt #3 140375-N0402-17 **1** Stamping, Prog. Die - 25 ton T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **3600 0.5**  **1 1**  0.047 **$0.45 $42.73**  **$15.50 $15.50**  **$0.02 $0.01**  **$0.00 $0.03**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.03 $0.03** 

14 V Bracket - W eld Stud, Brkt #3 140375-N0402-19 **1** Stamping, Prog. Die - 5 ton T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **3600 0.5**  **1 1**  0.066 **$0.45 $42.73**  **$15.50 $15.50**  **$0.03 $0.01**  **$0.00 $0.04**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.04 $0.04** 

15 V Bracket #4- Battery Tray Stamping 140375-N0402-21 **1** Stamping, Prog. Die - 2 ton T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **1800 0.5**  **1 1**  0.405 **$0.45 $42.73**  **$15.50 $15.50**  **$0.18 $0.01**  **$0.01 $0.20**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.22 $0.22** 

16 V Bracket #5 - Battery Tray W eldment 140375-N0402-23 **1** Weld, Spot - Bracket, Stand Off, Stud, etc. T2/T3 Mech. Assembly, SSLC Not Applicable Welding/Soldering Operator Mech. Assembly, LC **225 2**  **1 2**  0.000 **$0.00 $41.55**  **$100.00 $200.00**  **$0.00 $0.37**  **$0.89 $1.26**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.13**  **$1.39 $1.39** 

17 V Bracket #5 - Battery Tray Stamping 140375-N0402-24 **1** Stamping, Prog. Die - 200 ton T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS **1800 0.5**  **1 1**  0.721 **$0.45 $42.73**  **$42.91 $42.91**  **$0.32 $0.01**  **$0.02 $0.36**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.40 $0.40** 

18 V Bracket - Stand Off, Brkt #5 140375-N0402-26 **1** Stamping, Prog. Die - 25 ton T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **3600 0.5**  **1 1**  0.047 **$0.45 $42.73**  **$15.50 $15.50**  **$0.02 $0.01**  **$0.00 $0.03**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.03 $0.03** 

19 V Bracket - W eld Stud, Brkt #5 140375-N0402-28 **1** Stamping, Prog. Die - 5 ton T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **3600 0.5**  **1 1**  0.066 **$0.45 $42.73**  **$15.50 $15.50**  **$0.03 $0.01**  **$0.00 $0.04**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.04 $0.04** 

20 V Bracket #6 - Battery Tray W eldment 140375-N0402-30 **1** Weld, Projection - Bracket to Nut (12) T2/T3 Mech. Assembly, SSLC Not Applicable Welding/Soldering Operator Mech. Assembly, LC **150 2**  **1 3**  0.000 **$0.00 $41.55**  **$100.00 $300.00**  **$0.00 $0.55**  **$2.00 $2.55**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.26**  **$2.82 $2.82** 

21 V Bracket #6 - Battery Tray Stamping 140375-N0402-31 **1** Stamping, Prog. Die - 30 ton T2/T3 Stamp/Form, SSLC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **514 0.5**  **1 1**  2.534 **$0.45 $42.73**  **$15.50 $15.50**  **$1.14 $0.04**  **$0.03 $1.21**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.12**  **$1.34 $1.34** 



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 v Weld Nut - Projection 140380-N0402-01 **12** S **$0.00** $0.05 **$0.00 $0.60** 

2 v Weld Nut - Projection 140380-N0402-02 **3** S **$0.00** $0.05 **$0.00 $0.15** 

3 V Weld Stud 140380-N0402-03 **1** S **$0.00** $0.04 **$0.00 $0.04** 

4 V Weld Stud 140380-N0402-04 **1** S **$0.00** $0.04 **$0.00 $0.04** 

5 V Weld Stud 140380-N0402-05 **1** S **$0.00** $0.04 **$0.00 $0.04** 

6 v Weld Nut - Projection 140380-N0402-06 **12** S **$0.00** $0.04 **$0.00 $0.48** 

7 V Clip - Rosebud WH 140380-N0402-07 **1** Polypropylene S **$0.00** $0.05 **$0.00 $0.05**  

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or

Sub

- Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied

directly to T1 or OEM for Final or Sub

- Assembly. In addition

component material cost is accounted for in T1 quote sheet. Thus

component cost will only be included for Mark

- up Calculations.

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

**Mark-up $21.72** 

**T1 or OEM Total Manufacturing Cost: $6.44**  **$3.13 $9.96**  **$19.53 $0.07**  **$1.13 $0.90**  **$0.09 $2.19**  **$21.72**

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

----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%

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

----- ----- ----- **$0.15 $1.52**  **$1.74 $0.87**  **$4.28**

**Base Cost Impact to Vehicle: $6.44**  **$3.13 $9.96**  **$19.53 $0.22**  **$2.65 $2.64**  **$0.96 $6.47**  **$26.00 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $26.00**  **3 1** 



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 2 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 High Assembly Complexity**



## System Description: **Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid)** 

## Annual Component Volume: Shipping Method:

**Component Description: V Tray - Battery, Traction Battery Assembly**  

## Part Number: **140301-N0402-01** 

## We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process Description **OEM/Supplier**

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### 9,574

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Series Gasoline Hybrid**

**MARK-UP COSTS TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Full Q uote**  **Modification Q uote**  

### Di **ffe ren**  **tial Quote (Quote S um**  **mary in clu**  **des costing for both T echnology Packages)** 

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment**

**(%) Total # of** 

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Other #1**  **Other #1 Other #2**  **Other #2 Other #3**  **Other #3** 

### PACKAGING CALCULATIONS:

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers: **Reference Packaging Database for Additonal Infromation**

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

**Packaging**

**Cost per**

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



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



### Packaging Cost Total: **$0.000** 

### Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 3 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

**Purchase Part - High Impact Item (Full Cost Mapping)**

V Tray - Battery Assembly - Final w/Clip 140375-N0402-01

V Tray - Battery Assembly - W ash & Paint 140375-N0402-01

V Tray - Battery Assembly - Final W eldment 140375-N0402-01

V Tray - Battery W eldment 140375-N0402-02

V Tray - Battery Stamping 140375-N0402-03

V Bracket # 1 - Batt. Tray Stamping 140375-N0402-05



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **"**

**$0.00 $0.02**  **$0.08 $0.11**  **$0.00 $0.01**  **$0.00 $0.00**  **$0.01** Final Assembly - Snap on Rosebud Clip **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 3 1 1 3

**$0.00 $0.17**  **$0.51 $0.68**  **$0.00 $0.04**  **$0.03 $0.00**  **$0.07** Wa sh / Paint / Bake / Cure Final W eldment **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 443 1 30 443

**$0.00 $0.31**  **$0.75 $1.06**  **$0.00 $0.06**  **$0.04 $0.00**  **$0.11** We ld, Spot - Tray & Brackets #1 thru #6 **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 27 1 1 27

**$0.00 $0.55**  **$2.00 $2.55**  **$0.01 $0.15**  **$0.10 $0.00**  **$0.26** We ld, Projection - Bracket to Nut (12) **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 58 3 1 24

**$2.32 $0.08**  **$1.10 $3.49**  **$0.02 $0.24**  **$0.28 $0.07**  **$0.62** Stamping, Prog. Die - 2000 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 14 1 1 14

**$0.11 $0.01**  **$0.00 $0.12**  **$0.00 $0.01**  **$0.00 $0.00**  **$0.01** Stamping, Prog. Die - 2 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1 1 1 1 

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

V Bracket # 1 - Batt. Tray Stamping 140375-N0402-05

V Bracket #2 - Battery Tray W eldment 140375-N0402-07

V Bracket #2 - Battery Tray Stamping 140375-N0402-09

V Hinge Bracket - Access Door, Brkt #2 140375-N0402-10

V Bracket - W eld Stud, Brkt #2 140375-N0402-12

V Bracket #3 - Battery Tray W eldment 140375-N0402-14

V Bracket #3 - Battery Tray Stamping 140375-N0402-15

V Bracket - Stand Off, Brkt #3 140375-N0402-17

V Bracket - W eld Stud, Brkt #3 140375-N0402-19

V Bracket #4- Battery Tray Stamping 140375-N0402-21

V Bracket #5 - Battery Tray W eldment 140375-N0402-23

V Bracket #5 - Battery Tray Stamping 140375-N0402-24

V Bracket - Stand Off, Brkt #5 140375-N0402-26

V Bracket - W eld Stud, Brkt #5 140375-N0402-28

V Bracket #6 - Battery Tray W eldment 140375-N0402-30

V Bracket #6 - Battery Tray Stamping 140375-N0402-31



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

v Weld Nut - Projection 140380-N0402-01

v Weld Nut - Projection 140380-N0402-02

V Weld Stud 140380-N0402-03

V Weld Stud 140380-N0402-04

V Weld Stud 140380-N0402-05

v Weld Nut - Projection 140380-N0402-06

V Clip - Rosebud WH 140380-N0402-07 **$0.11 $0.01**  **$0.00 $0.12**  **$0.00 $0.01**  **$0.00 $0.00**  **$0.01** Stamping, Prog. Die - 2 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1 1 1 1

**$0.00 $0.55**  **$1.33 $1.89**  **$0.01 $0.11**  **$0.08 $0.00**  **$0.19** We ld, Spot - Bracket, Access Door, Stud, etc. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 46 2 1 24

**$0.45 $0.06**  **$0.39 $0.90**  **$0.01 $0.06**  **$0.07 $0.02**  **$0.16** Stamping, Prog. Die - 1000 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 10 1 1 10

**$0.07 $0.01**  **$0.01 $0.09**  **$0.00 $0.01**  **$0.00 $0.00**  **$0.01** Stamping, Prog. Die - 25 ton **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  **15.98** 1 1 1 1

**$0.03 $0.01**  **$0.00 $0.05**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Stamping, Prog. Die - 5 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1 1 1 1

**$0.00 $0.32**  **$0.78 $1.10**  **$0.00 $0.07**  **$0.04 $0.00**  **$0.11** We ld, Spot - Bracket, Stand Off, Stud, etc. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 27 2 1 14

**$0.32 $0.01**  **$0.02 $0.36**  **$0.00 $0.02**  **$0.01 $0.00**  **$0.04** Stamping, Prog. Die - 200 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 2 1 1 2

**$0.02 $0.01**  **$0.00 $0.03**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Stamping, Prog. Die - 25 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1 1 1 1

**$0.03 $0.01**  **$0.00 $0.04**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Stamping, Prog. Die - 5 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1 1 1 1

**$0.18 $0.01**  **$0.01 $0.20**  **$0.00 $0.01**  **$0.01 $0.00**  **$0.02** Stamping, Prog. Die - 2 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 2 1 1 2

**$0.00 $0.37**  **$0.89 $1.26**  **$0.00 $0.08**  **$0.05 $0.00**  **$0.13** We ld, Spot - Bracket, Stand Off, Stud, etc. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 30 2 1 16

**$0.32 $0.01**  **$0.02 $0.36**  **$0.00 $0.02**  **$0.01 $0.00**  **$0.04** Stamping, Prog. Die - 200 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 2 1 1 2

**$0.02 $0.01**  **$0.00 $0.03**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Stamping, Prog. Die - 25 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1 1 1 1

**$0.03 $0.01**  **$0.00 $0.04**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Stamping, Prog. Die - 5 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1 1 1 1

**$0.00 $0.55**  **$2.00 $2.55**  **$0.01 $0.15**  **$0.10 $0.00**  **$0.26** We ld, Projection - Bracket to Nut (12) **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 47 3 1 24

**$1.14 $0.04**  **$0.03 $1.21**  **$0.00 $0.07**  **$0.05 $0.00**  **$0.12** Stamping, Prog. Die - 30 ton **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 7 1 1 7

**$0.60 $0.60** 

**$0.15 $0.15** 

**$0.04 $0.04** 

**$0.04 $0.04** 

**$0.04 $0.04** 

**$0.48 $0.48** 

**$0.05 $0.05** 

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

**Total**

**$6.44 $3.13**  **$9.96 $19.53**  **$0.07 $1.13**  **$0.90 $0.09**  **$2.19**

**$21.72 2** 



### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 4 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Material **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **"** 

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 5 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

**Purchase Part - High Impact Item (Full Cost Mapping)**

V Tray - Battery Assembly - Final w/Clip 140375-N0402-01

V Tray - Battery Assembly - W ash & Paint 140375-N0402-01

V Tray - Battery Assembly - Final W eldment 140375-N0402-01

V Tray - Battery W eldment 140375-N0402-02

V Tray - Battery Stamping 140375-N0402-03

V Bracket # 1 - Batt. Tray Stamping 140375-N0402-05



### GENERAL COMPONENT INFORMATION 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**

**1.0 1.0**  **1200 3.00**  1.00

**1.0 1.0**  **244 14.77**  1.00

**1.0 1.0**  **133 27.00**  1.00

**3.0 1.0**  **150 24.00**  2.00

**1.0 1.0**  **257 14.00**  0.50

**1.0 1.0**  **3600 1.00**  0.50 

### Project Process Requirement

V Bracket # 1 - Batt. Tray Stamping 140375-N0402-05

V Bracket #2 - Battery Tray W eldment 140375-N0402-07

V Bracket #2 - Battery Tray Stamping 140375-N0402-09

V Hinge Bracket - Access Door, Brkt #2 140375-N0402-10

V Bracket - W eld Stud, Brkt #2 140375-N0402-12

V Bracket #3 - Battery Tray W eldment 140375-N0402-14

V Bracket #3 - Battery Tray Stamping 140375-N0402-15

V Bracket - Stand Off, Brkt #3 140375-N0402-17

V Bracket - W eld Stud, Brkt #3 140375-N0402-19

V Bracket #4- Battery Tray Stamping 140375-N0402-21

V Bracket #5 - Battery Tray W eldment 140375-N0402-23

V Bracket #5 - Battery Tray Stamping 140375-N0402-24

V Bracket - Stand Off, Brkt #5 140375-N0402-26

V Bracket - W eld Stud, Brkt #5 140375-N0402-28

V Bracket #6 - Battery Tray W eldment 140375-N0402-30

V Bracket #6 - Battery Tray Stamping 140375-N0402-31



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

v Weld Nut - Projection 140380-N0402-01

v Weld Nut - Projection 140380-N0402-02

V Weld Stud 140380-N0402-03

V Weld Stud 140380-N0402-04

V Weld Stud 140380-N0402-05

v Weld Nut - Projection 140380-N0402-06

V Clip - Rosebud WH 140380-N0402-07 **1.0 1.0**  **3600 1.00**  0.50

**2.0 1.0**  **150 24.00**  2.00

**1.0 1.0**  **360 10.00**  0.50

**1.0 1.0**  **3600 1.00**  0.50

**1.0 1.0**  **3600 1.00**  1.00

**2.0 1.0**  **257 14.00**  2.00

**1.0 1.0**  **1800 2.00**  0.50

**1.0 1.0**  **3600 1.00**  0.50

**1.0 1.0**  **3600 1.00**  0.50

**1.0 1.0**  **1800 2.00**  0.50

**2.0 1.0**  **225 16.00**  2.00

**1.0 1.0**  **1800 2.00**  0.50

**1.0 1.0**  **3600 1.00**  0.50

**1.0 1.0**  **3600 1.00**  0.50

**3.0 1.0**  **150 24.00**  2.00

**1.0 1.0**  **514 7.00**  0.50



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 6 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Project Process Requirement

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

# An **ode slurry: $/Kg**  **% Content $/Lb @ %** 

– graphite 45-50% 20.00 $ 47.5% 4.31 $

(some companies looking at cheaper Mesophasepitch fibers

(ex Conoco or Petoca; 10-30 USD/kg)

– conductive carbon black 4-6% 30.00 $ 5.0% 0.68 $

(Super P ex Erachem, Ketjen Black ex Akzo, Black Pearls 2000

(ex Cabot; price approx 30 USD/kg)

– binder 2-4% 18.00 $ 2.0% 0.16 $

(PVDF ex Atochem, 18USD/kg)

– solvent + plasticiser to 100% 3.86 $ 45.5% 0.80 $

(acetone or NMP very often, DBP)

100.0% **5.95 $** 

**Cathode slurry: $/Kg**  **% Content $/Lb @ %** 

– NiMH (Nickel Hy droxide) 35-40% 83.00 $ 37.5% 14.12 $

(price approx. 83 USD/kg)

– Conductive carbon black 6-9% 30.00 $ 7.5% 1.02 $

(same as anode)

– binder 2-4% 18.00 $ 3.0% 0.24 $

(PVDF ex Atochem)

– solvent + plasticiser to 100% 3.86 $ 52.0% 0.91 $

(acetone or NMP usually , DBP)

100.0% **16.29 $** 

# Sense Check: 0.0005 lb/2.15" single sq. = 0.002791 lbs/ft

0.002791 lbs/ft x 10'/cell = 0.027907 lbs/cell

60 cells/battery

x 0.027907 lbs/cell =

# 1.674419 lbs/battery

# 8.00

$

13.40 $

**$13.40/battery compared to calculated $0.03/ft x 600 feet/battery = $18.00**

cost estimate (per lb.) based $8K/ton (mat'l cost) and assuming

"2 x mat'l" for extrusion, processing, mark-up = $16K/ton ($8/lb)

# $192.16 / 20 = $9.61 per litre

Cell cavity

= 0.61" x 2.14" = 1.3054 cubic "

1.3054 cubic " = 0.02139 L

# 0.02139 L x 10 cavities/cell x 0.25 factor * = 0.2139 L/cell 0.32085 L /Battery =

* 0.25 factor represents net remaining cavity volum e after displacement by electrode stack

# $3.08

# $29.69 Tool V Electrode and First Fixture 0.0000

Separator Assy

$29.69 P.-P. Part V Electrode and V Electrode Plate Postive V Slurry- Binder 5.0000

Separator Assy Cathode

$29.69 Tool V Electrode Plate First Fixture 1.0000

Postive

$29.69 Part V Electrode Plate V Slurry - Binder Cathode V Slurry- Binder 0.0000

Postive Cathode

$29.69 Operation V Electrode Plate Mix Slurrry 1.0000

Postive

$29.69 Part V Electrode Plate V Electrode Foil- Postive Cathode V Electrode Foil- 1.0000

Postive Postive Cathode

$29.69 Tool V Electrode Plate Rollers 1.0000

Postive

$29.69 Operation V Electrode Plate Coat Appilcation 1.0000

Postive

$29.69 Tool V Electrode Plate Electrode Knife 6.0000

Postive

$29.69 Operation V Electrode Plate Compress Foil 3.0000

Postive

$29.69 Tool V Electrode Plate Oven 1.0000

Postive

$29.69 Operation V Electrode Plate Dry 0.0000

Postive

$29.69 Tool V Electrode Plate Clean Room 1.0000

Postive

$29.69 Tool V Electrode Plate Deburing Equipment 1.0000

Postive

$29.69 Operation V Electrode Plate Deburr Foil 1.0000

Postive

$29.69 Tool V Electrode Plate Cutting Tool 4.0000

Postive

$29.69 Operation V Electrode Plate Cutting To Size 0.0000

Postive

$29.69 P.-P. Part V Electrode and V Electrode Plate Negative V Electrode Plate 0.0000

Separator Assy Negative

$29.69 Tool V Electrode Plate First Fixture 1.0000

Negative

$29.69 Part V Electrode Plate V Carbon Slurry - Anode V Carbon Slurry - 1.0000

Negative Electrode Anode Electrode

$29.69 Operation V Electrode Plate Mix Slurrry 4.0000

Negative

$29.69 Tool V Electrode Plate Rollers 1.0000

Negative

$29.69 Part V Electrode Plate V Electrode Copper Foil - Neg. V Electrode Plate 1.0000

Negative (Anode) Negative

$29.69 Operation V Electrode Plate Coat Appilcation 1.0000

Negative

$29.69 Tool V Electrode Plate Electrode Knife 6.0000

# Negative

$29.69 Operation V Electrode Plate Compress Foil 3.0000

Negative

$29.69 Tool V Electrode Plate Oven 1.0000

Negative

$29.69 Operation V Electrode Plate Dry 0.0000

Negative

$29.69 Tool V Electrode Plate Clean Room 1.0000

Negative

$29.69 Tool V Electrode Plate Deburing Equipment 1.0000

Negative

$29.69 Operation V Electrode Plate Deburr Foil 1.0000

Negative

$29.69 Tool V Electrode Plate Cutting Tool 3.0000

Negative

$29.69 Operation V Electrode Plate Cutting To Size 2.0000

Negative

$29.69 Fastening V Electrode and Stake in Place 0.0000

Separator Assy

$29.69 Operation V Electrode and Connect Electrodes 2.0000

Separator Assy

$29.69 Part V Electrode and V Electrode Separator Paper V Electrode 1.0000

Separator Assy Separator Paper

$29.69 Tool V Electrode and Clamp 0.0000

Separator Assy

$29.69 Operation V Electrode and Insert Electrode-Separator 3.0000

Separator Assy

$29.69 Tool V Electrode and Seam W elder 3.0000

Separator Assy

$29.69 Fastening V Electrode and Seam W eld 0.0000

Separator Assy

$43.52 Operation V Battery Cell Insert Electrode Stack 1.0000

Case

$43.52 Tool V Battery Cell Projection W elder 3.0000

Case

$43.52 Fastening V Battery Cell Projection W eld 20.0000

Case

$43.52 Tool V Battery Cell Heat W eld Tool 2.0000

Case

$43.52 Fastening V Battery Cell Heat W eld Seams 0.0000

Case

$43.52 Subassembly V Battery Cell V Seal Piston - Battery Vent V Seal Piston - 2.0000

Case Battery Vent

$43.52 Tool V Seal Piston - First Fixture 0.0000

Battery Vent

$43.52 P.-P. Part V Seal Piston - V Piston - Vent Seal V Piston - Vent 2.0000

Battery Vent Seal

$43.52 Tool V Piston - Vent Injection Molding Machine

-

Seal

$43.52 Part V Piston - Vent V Piston - Vent Seal V Piston - Vent

-

# Seal Seal

- - - Mat Cost=$.001, Cycle Time=.74

- 4.0000

sec

- - - 5 ton press, 10 cavities, part

- 0.0000

cost=$.011

$43.52 P.-P. Part V Seal Piston - V Seal - Battery Vent V Seal - Battery 4.0000

Battery Vent Vent

$43.52 Tool V Seal - Battery Injection Molding Machine

-

Vent

$43.52 Part V Seal - Battery V Seal - Battery Vent V Seal - Battery

-

Vent Vent

- - - Material Req'd=.0011 lbs., Cycle

- 1.0000

Time= .437 sec

- - - Part Cost= $.007, 4 Ton Press,

- 7.0000

10 mold Cav

$43.52 Fastening V Seal Piston - Snap Together 3.0000

Battery Vent

$43.52 Part V Battery Cell V Spring - Battery Vent V Spring - Battery 3.0000

Case Vent

$43.52 Fastening V Battery Cell Press Together 0.0000

Case

$43.52 P.-P. Part V Battery Cell V Cap - Battery Vent V Cap - Battery 3.0000

Case Vent

$43.52 Tool V Cap - Battery Injection Molding Machine

-

Vent

$43.52 Part V Cap - Battery V Cap - Battery Vent V Cap - Battery

-

Vent Vent

- - - Mat'l Req'd=.003 lbs, Cycle

- 1.0000

time/part=.685 sec.

- - - Part Cost=$.012, press=10 tons,

- 3.0000

10 cavities

$43.52 Fastening V Battery Cell Snap Together 0.0000

Case

$43.52 Operation V Battery Cell Flip Asm

Case 0.0000

$0.00 P.-P. Part V Battery Cell Electrolyte - Potasium Hydroxide Electrolyte -

Case Potasium

Hydroxide 60.0000

$0.00 Tool Electrolyte - First Fixture

Potasium

Hydroxide

$0.00 Tool Electrolyte - Battery Dry Room

Potasium

Hydroxide 5.0000

$0.00 Operation Electrolyte - Heat Dry Battery

Potasium sec

Hydroxide 10.0000

$0.00 Tool Electrolyte - Vaccum Fill Equipment

Potasium

Hydroxide 3.0000

# $0.00 Operation Electrolyte - Vaccum Fill Electrolyte

Potasium

Hydroxide 20.0000

$0.00 Tool Electrolyte - Heat W eld

Potasium

Hydroxide 7.0000

$0.00 Fastening Electrolyte - Heat W eld Seams

Potasium 7.0000

Hydroxide

$43.52 Part V Battery Cell V Foil Applique - BAttery Sides V Foil Applique - 7.0000

Case BAttery Sides

$43.52 Part V Battery Cell v Foil Applique - Battery Bottom v Foil Applique - 3.0000

Case Battery Bottom

$43.52 Part V Battery Cell V Foil Applique - Battery Top V Foil Applique - 1.0000

Case Battery Top

$43.52 Fastening V Battery Cell Apply Label 2.0000

Case

$43.52 Tool V Battery Cell Rollers 5.0000

Case

$43.52 Fastening V Battery Cell PUSH ON 3.0000

Case

$43.52 Part V Battery Cell V Label - Battery Cell Bar Code V Label - Battery 10.0000

Case Cell Bar Code

$43.52 Fastening V Battery Cell Apply Label

Case

$43.52 Tool V Battery Cell Battery Formation Tool

Case

$43.52 Operation V Battery Cell Charge-Discharge Batteries 5.0000

Case sec

$43.52 Operation V Battery Cell Store and Age Batteries 30.0000

Case sec

$43.52 Tool V Battery Cell Battery Functional Check 8.0000

Case

$43.52 Inspect V Battery Cell Battery Acceptance Testing 0.0000

Case

$0.00 P.-P. Part V Battery Module V Separator - Battery Chassis V Separator - 8.0000

- NMH Battery Chassis

$0.00 Tool V Separator - First Fixture

-

Battery Chassis

$0.00 Part V Separator - V Separator - Battery Chassis V Separator - 3.0000

Battery Chassis Battery Chassis

- - - Extrusion Mat'l Cost= $1.55 / lb

- 2.0000

x .1622 = $.25/pc

$29.69 Tool V Battery Module Hand Tool 3.0000

- NMH

$29.69 Fastening V Battery Module Push In Place 6.0000

- NMH

$29.69 Operation V Battery Module TURN OVER 6.0000

- NMH

$29.69 Subassembly V Battery Module V Sensor - Battery Temp V Sensor - 3.0000

# - NMH Battery Temp

$29.69 Part V Battery Module V Danger Label - Battery Module V Danger Label - 2.0000

- NMH Battery Module

$29.69 Fastening V Battery Module Apply Label 3.0000

- NMH

$29.69 Fastening V Battery Module Push In Place 8.0000

- NMH

$29.69 Operation V Battery Module TURN OVER

- NMH 0.0000

$29.69 Subassembly V Battery Module VTerminal Post Bracket - Battery V Pos Terminal

- NMH Post Bracket - 8.0000

Battery

$29.69 Tool VTerminal Post First Fixture

Bracket - Battery 0.0000

$29.69 P.-P. Part VTerminal Post V Pos Terminal Post Bracket - V Pos Terminal

Bracket - Battery Battery Post Bracket -

Battery 0.0000

$29.69 Tool V Pos Terminal Stamping Press

Post Bracket -

Battery 8.0000

$29.69 Tool V Pos Terminal Stamping Press

Post Bracket -

Battery

- $29.69 Part V Pos Terminal V Pos Terminal Post Bracket - V Pos Terminal

Post Bracket - Battery Post Bracket -

-

Battery Battery

- - - Mat'l Blank W eight=.344 lbs.,

- 8.0000

Mat'l Cost= $.56

- - - Prog Die time = .7 sec., Press

-

Tonnage= 60 Tons 0.0000

$0.00 P.-P. Part VTerminal Post V Neg Terminal Post Bracket - V Pos Terminal

Bracket - Battery Battery Post Bracket -

Battery 8.0000

$0.00 Tool V Neg Terminal First Fixture

Post Bracket -

Battery

- $0.00 Part V Neg Terminal V Neg Terminal Post Bracket - V Pos Terminal

Post Bracket - Battery Post Bracket -

-

Battery Battery

- - - Mat'l Blank W eight=.344 lbs.,

- 0.0000

Mat'l Cost= $.56

- - - Prog Die time = .7 sec., Press

- 2.0000

Tonnage= 60 Tons

$29.69 Tool VTerminal Post Press 3.0000

Bracket - Battery

$29.69 Part VTerminal Post V Stud - Batt. Cell Terminal V Stud - Batt. Cell 6.0000

Bracket - Battery Terminal

$29.69 Fastening VTerminal Post Press Together 4.0000

Bracket - Battery

$29.69 Part VTerminal Post V Insulator strip - Batt. Terminal V Insulator strip - 3.0000

# Bracket - Battery Batt. Terminal

$29.69 Operation VTerminal Post Peel Off Adhesive Backing 7.0000

Bracket - Battery

$29.69 Fastening VTerminal Post Apply Label 4.0000

Bracket - Battery

$29.69 Part VTerminal Post v Label - Part No. Manuf. v Label - Part No. 3.0000

Bracket - Battery Manuf.

$29.69 Operation VTerminal Post Peel Off Adhesive Backing 3.0000

Bracket - Battery

$29.69 Operation VTerminal Post Flip Asm 6.0000

Bracket - Battery

$29.69 Fastening VTerminal Post Apply Label

Bracket - Battery

$29.69 Tool VTerminal Post Oven 4.0000

Bracket - Battery

$29.69 Operation VTerminal Post Bake and Cure Insulator / label

Bracket - Battery sec 5.0000

$29.69 Part V Battery Module V Screw Terminal Post Bracket - V Screw Terminal

- NMH Battery Post Bracket - 3.0000

Battery

$0.00 Part V Battery V Screw - Battery module - tray V Screw - Battery 7.0000

Subsystem module - tray

$0.00 Tool V Battery Hand Tool 2.0000

Subsystem

$0.00 Fastening V Battery Manual Screw 4.0000

Subsystem

$0.00 Operation V Battery 18" Move

-

Subsystem

$29.69 Subassembly V Battery V Cable-Positive Battery Short V Cable-Positive 4.0000

Subsystem Battery 3-6

- - - 14 inch cable x $1.13/foot+.40

- -

terminals= $1.71

$29.69 Subassembly V Battery V Cable-Positive Battery 1-4 V Cable-Positive 5.0000

Subsystem Battery 1-4

- - - 14 inch cable x $1.13/foot+.40

-

terminals= $1.71

-

$29.69 Subassembly V Battery V Cable-Positive Battery V Cable-Positive

Subsystem 2-Service Terminal Battery 2-Service 3.0000

Terminal

- - - 24" cable x $1.13/foot+.40

-

term.+ .08 conduit/tape

-

$29.69 Subassembly V Battery V Cable-Negative Cable Service V Cable-Negative

Subsystem Terminal Cable 5- Service 3.0000

Terminal

- - - 11.5"cbl x$1.13/foot+.40

- 7.0000

term.+.04 conduit/tape

$0.00 Part V Battery V Tie W rap V Tie W rap

Subsystem Cables

$0.00 Multitouch V Battery V Harness-Battery Pack V 5.0000

Subsystem Assembly Route Harness-Battery

# Pack Assembly

Route 5.0000

$0.00 Multitouch V Battery V Harness-Battery Pack Signal V

Subsystem Wi re Eyelets Harness-Battery

Pack Assembly 1.0000

$0.00 Multitouch V Battery V Harness - Battery Temp Sensor V Harness -

Subsystem Battery Temp 2.0000

Sensor

$0.00 Fastening V Battery Snap Together 4.0000

Subsystem

$0.00 Part V Battery V Nut Cable to Battery Terrminal V Nut Cable to 4.0000

Subsystem Battery Terrminal

$0.00 Tool V Battery Power Tool 1.0000

Subsystem

$0.00 Fastening V Battery Power Screw 2.0000

Subsystem

$0.00 Operation V Battery CDI

Subsystem 2.0000

$0.00 Part V Battery V Cover- Battery Terminal V Cover- Battery

Subsystem Protective Terminal

Protective

0 Fastening V Battery Push In Place 2.0000 sec

Subsystem

# sec **0.0000 sec** $0.00 $0.00 60 $0.00

sec **5.0000 sec** $0.00 $0.04 840 $0.00

sec **0.0000 sec** $0.00 $0.00 840 $0.00

sec **5.0000 sec** $0.00 $0.04 840 $0.00

sec **1.0000 sec** $0.00 $0.01 840 $0.00

sec **0.0000 sec** $0.00 $0.00 840 $0.00

sec **1.0000 sec** $0.00 $0.01 840 $0.00

sec **1.0000 sec** $0.00 $0.01 840 $0.00

sec **1.0000 sec** $0.00 $0.01 840 $0.00

sec **1.0000 sec** $0.00 $0.01 840 $0.00

sec **6.0000 sec** $0.00 $0.05 840 $0.00

sec **3.0000 sec** $0.00 $0.02 840 $0.00

sec **1.0000 sec** $0.00 $0.01 840 $0.00

sec **0.0000 sec** $0.00 $0.00 840 $0.00

sec **1.0000 sec** $0.00 $0.01 840 $0.00

sec **1.0000 sec** $0.00 $0.01 840 $0.00

sec **1.0000 sec** $0.00 $0.01 840 $0.00

sec **4.0000 sec** $0.00 $0.03 840 $0.00

sec **0.0000 sec** $0.00 $0.00 840 $0.00

sec **0.0000 sec** $0.00 $0.00 840 $0.00

sec **1.0000 sec** $0.00 $0.01 840 $0.00

sec **1.0000 sec** $0.00 $0.01 840 $0.00

sec **4.0000 sec** $0.00 $0.03 840 $0.00

sec **1.0000 sec** $0.00 $0.01 840 $0.00

sec **1.0000 sec** $0.00 $0.01 840 $0.00

# sec **1.0000 sec** $0.00 $0.01 840 $0.00

sec **6.0000 sec** $0.00 $0.05 840 $0.00

sec **3.0000 sec** $0.00 $0.02 840 $0.00

sec **1.0000 sec** $0.00 $0.01 840 $0.00

sec **0.0000 sec** $0.00 $0.00 840 $0.00

sec **1.0000 sec** $0.00 $0.01 840 $0.00

sec **1.0000 sec** $0.00 $0.01 840 $0.00

sec **1.0000 sec** $0.00 $0.01 840 $0.00

sec **3.0000 sec** $0.00 $0.02 1,680 $0.00

sec **2.0000 sec** $0.00 $0.02 1,680 $0.00

sec **0.0000 sec** $0.00 $0.00 60 $0.00

sec **2.0000 sec** $0.00 $0.02 60 $0.00

sec **1.0000 sec** $0.00 $0.01 60 $0.00

sec **0.0000 sec** $0.00 $0.00 60 $0.00

sec **3.0000 sec** $0.00 $0.02 1,680 $0.00

sec **3.0000 sec** $0.00 $0.04 60 $0.00

sec **0.0000 sec** $0.00 $0.00 6 $0.00

0 sec **1.0000 sec** $0.00 $0.01 120 $0.00

sec **3.0000 sec** $0.00 $0.04 6 $0.00

sec **20.0000 sec** $0.00 $0.24 6 $0.00

sec **2.0000 sec**

- $0.02 6

-

sec **0.0000 sec** $0.00 $0.00 6 $0.00

sec **2.0000 sec**

- $0.02 6

-

**0.0000 sec** $0.00 $0.00 6 $0.00

**2.0000 sec** $0.01 $0.02 6 $0.06

# sec

**-** - - - -

sec

**-** - - - -

sec **4.0000 sec**

- $0.05 6

-

**0.0000 sec** $0.00 $0.00 6 $0.00

**4.0000 sec** $0.00 $0.05 6 $0.01

sec

**-** - - - -

sec

**-** - - - -

sec **1.0000 sec** $0.00 $0.01 6 $0.00

sec **7.0000 sec** $0.00 $0.08 6 $0.00

sec **3.0000 sec** $0.00 $0.04 6 $0.00

sec **3.0000 sec** $0.00 $0.04 6 $0.00

**0.0000 sec** $0.00 $0.00 6 $0.00

**3.0000 sec** $0.00 $0.04 6 $0.00

sec

**-** - - - -

sec

**-** - - - -

sec **1.0000 sec** $0.00 $0.01 6 $0.00

**3.0000 sec** $0.00 $0.04 6 $0.00

sec

**0.0000 sec** $0.00 $0.00 6 $0.00

0 sec

**0.0000 sec** $0.00 $0.00 6 $0.00

**60.0000 sec** $0.00 $0.00 6 $0.00

sec

**3,600.00** $0.00 $0.00 6 $0.00

**sec**

0 sec

**5.0000 sec** $0.00 $0.00 6 $0.00

sec

# 10.0000 sec $0.00 $0.00 6 $0.00

0 sec

**3.0000 sec** $0.00 $0.00 6 $0.00

sec

**20.0000 sec** $0.00 $0.00 6 $0.00

sec

sec **7.0000 sec** $0.00 $0.08 12 $0.00

sec **7.0000 sec** $0.00 $0.08 6 $0.00

sec **7.0000 sec** $0.00 $0.08 6 $0.00

sec **3.0000 sec** $0.00 $0.04 48 $0.00

sec **1.0000 sec** $0.00 $0.01 6 $0.00

sec **2.0000 sec** $0.00 $0.02 48 $0.00

0 sec **5.0000 sec** $0.00 $0.06 6 $0.00

**3.0000 sec** $0.00 $0.04 6 $0.00

**10.0000 sec** $0.00 $0.12 6 $0.00

sec **3,600.00** $0.00 $43.52 6 $0.00

**sec**

0 sec **3,600.00** $0.00 $43.52 6 $0.00

**sec**

sec **5.0000 sec** $0.00 $0.06 6 $0.00

sec **30.0000 sec** $0.00 $0.36 6 $0.00

sec **8.0000 sec** $0.00 $0.07 6 $0.00

**0.0000 sec** $0.00 $0.00 6 $0.00

sec **8.0000 sec** $0.00 $0.00 12 $0.00

sec

**-** - - - -

sec **3.0000 sec** $0.00 $0.02 3 $0.00

sec **2.0000 sec** $0.00 $0.02 6 $0.00

sec **3.0000 sec** $0.00 $0.02 3 $0.00

sec **6.0000 sec** $0.00 $0.05 3 $0.00

# sec **6.0000 sec** $0.00 $0.05 3 $0.00

sec **3.0000 sec** $0.00 $0.02 3 $0.00

sec **2.0000 sec** $0.00 $0.02 6 $0.00

**3.0000 sec** $0.00 $0.02 3 $0.00

sec

**8.0000 sec** $0.00 $0.07 3 $0.00

sec

**0.0000 sec** $0.00 $0.00 3 $0.00

sec

**8.0000 sec** $0.00 $0.07 3 $0.00

sec

**0.0000 sec** $0.00 $0.00 3 $0.00

sec

**0.0000 sec** $0.00 $0.00 3 $0.00

**8.0000 sec** $0.00 $0.07 3 $0.00

sec

**-** - - - -

**-** - - - -

sec

**8.0000 sec** $0.00 $0.07 3 $0.00

sec

**0.0000 sec** $0.00 $0.00 3 $0.00

**8.0000 sec** $0.00 $0.00 3 $0.00

sec

**-** - - - -

sec

**-** - - - -

sec **0.0000 sec** $0.00 $0.00 3 $0.00

sec **2.0000 sec** $0.00 $0.02 6 $0.00

sec **3.0000 sec** $0.00 $0.02 6 $0.00

sec **6.0000 sec** $0.00 $0.05 3 $0.00

# sec **4.0000 sec** $0.00 $0.03 3 $0.00

sec **3.0000 sec** $0.00 $0.02 3 $0.00

sec **7.0000 sec** $0.00 $0.06 6 $0.00

sec **4.0000 sec** $0.00 $0.03 6 $0.00

sec **3.0000 sec** $0.00 $0.02 3 $0.00

**3.0000 sec** $0.00 $0.02 6 $0.00

sec **6.0000 sec** $0.00 $0.05 3 $0.00

**360.0000** $0.00 $2.97 3 $0.00

sec **sec**

**4.0000 sec** $0.00 $0.03 12 $0.00

sec

sec **5.0000 sec** $0.00 $0.00 12 $0.00

sec **3.0000 sec** $0.00 $0.00 1 $0.00

sec **7.0000 sec** $0.00 $0.00 12 $0.00

**2.0000 sec** $0.00 $0.00 1 $0.00

sec **4.0000 sec** $1.71 $0.00 1 $1.71

**-** - - - -

sec **4.0000 sec** $1.71 $0.00 1 $1.71

**-** - - - -

**5.0000 sec** $2.74 $0.00 1 $2.74

sec

**-** - - - -

**3.0000 sec** $1.52 $0.00 1 $1.52

sec

sec

**-** - - - -

**3.0000 sec** $0.00 $0.00 2 $0.00

sec **7.0000 sec** $0.00 $0.00 3 $0.00

# sec

**5.0000 sec** $0.00 $0.00 4 $0.00

sec

**5.0000 sec** $0.00 $0.00 3 $0.00

sec

sec **1.0000 sec** $0.00 $0.00 3 $0.00

sec **2.0000 sec** $0.00 $0.00 7 $0.00

sec **4.0000 sec** $0.00 $0.00 1 $0.00

sec **4.0000 sec** $0.00 $0.00 7 $0.00

**1.0000 sec** $0.00 $0.00 1 $0.00

sec

**2.0000 sec** $0.00 $0.00 4 $0.00

**2.0000 sec** 0 0 4 0

# Height Wi dth Thickness We ight/pc

cm3 g/cm3 (grams)

Cathode (+) Alum inum Foil 6.5 5.4 0.002 0.0702 2.70 0.19

Anode (-) Copper Foil 6.5 5.4 0.002 0.0702 8.92 0.63 (cm) Density

Factor

# $/Lb. $/g

$1.50 $0.00331 $0.00063

$4.20 $0.00926 $0.00580

# V Battery

Module - NMH

V Carrier - Battery

Module

V Chassis Side Panel - Batt. Module

V Straps- Battery

Module Chassis

V Battery

- NiMH (Assembled, Charged, & Tested)

V Battery

- NiMH (Assembled)

V Battery

Cell Case Lid

V Battery

Cell Case Outer W alls

V Battery

Cell Case Terminal Carrier (Assembled)

V Battery

Cell Case Terminal Carrier (Molded)

V Post-Cell Terminal Contact

V Post Plate - Terminal Lug Bar Stock

V Lug Post - Terminal Bar Stock

V Battery

Cell Case Floor

V Electrode and Separator Assy

V Electrode Plate Postive

V Slurry - Binder Cathode

V Electrode Foil- Postive Cathode

V Electrode Plate Negative

V Carbon Slurry

- Anode Electrode

V Electrode Copper Foil - Neg. (Anode)

V Seal Piston - Battery

Vent

V Piston - Vent Seal

V Seal - Battery

Vent

V Cap - Battery

Vent

Electroly te - Potasium Hy droxide

V Sensor - Battery

Temp

v Label - Part No. Manuf.

V Screw Terminal Post Bracket - Battery

V Screw - Battery

module - tray

V Tie W rap

V Nut Cable to Battery

Terrminal

V Stud - Batt. Cell Terminal

V Seals - Seals Terminal Posts

V Electrode Separator Paper

V Spring - Battery

Vent

V Label - Battery

Cell Bar Code

# Seconds

Mix Slurry 2,700

Apply to Foil Sheet (2 sides) 300

Dry Sheet 1,200

Cut Sheet to Plates 300

4,500 / 2,687 = 1.6747 seconds each x 1.05

(process loss)

Sheet size/batch = 72 " x 216 " = ##### sq inches

Plate size = 2.12 " x 2.6 " = 5.512 sq inches

Plate Yield per Batch = 15,552 / 5.512 = 2,821 / 1.05 = 2,687

(yield loss)

# = 1.75839

(process loss)

# ELECTRODE PLA **TE MA NUFA**  **CTURING CELL CONFIGURA TIONS** 

28-Jan-09

**Cell Electrode Wrapper** 450K/y r x 60 wrappers/battery = 27.0M wrappers/y r **"Accordion Stack"**

Operation Load

Electrode

Plate

Positive

(14 pcs) Load

Electrode

Plate

Negative

(14 pcs) Stake in

Place

(28 pcs) Connect

Electrodes

(28 pcs) Apply

Electrode

Separator

Paper

(Film) Clam p Insert

Electrode

Stack

Separator Seam

We lder

Cy cle Time 70 56 84 56 0 2 1 0

Supplier

Est. Cost

Voltage

Am perage

Wa tts

Air

Other

**Electrode Plate Positive** 450K/y r x 840 plates/battery = 378.0M (+) plates/y r

**Electrode Plate Negative** 450K/y r x 840 plates/battery = 378.0M (-) plates/y r **"Carbon Wafer"**

Operation Slurry

-

Cathode/

Anode Mix

Slurrry Electrode

Foil Rollers Coat

Appilcation Electrode

Knife Compres

s Foil Oven

Cy cle Time 0 1 4 1 1 1 1 6

Supplier

Est. Cost

Voltage

Am perage

Wa tts

Air

Other

**Electrolyte - Potassium Hydroxide** 450K/y r x 6 cells/battery = 2.7M cells/y r

Operation Move

Battery to

Dry Room Heat Dry

Battery Move to

Vaccum Fill

Equipm ent Vaccum

Fill

Electroly te Move to

Heat W eld Heat

We ld

Seam s

Cy cle Time 60 3600 5 10 3 20

Supplier

Est. Cost

Voltage

Am perage

Wa tts

Air

Other

# "Accordion Stack"

Seam

We ld

Electrode

Tabs

(28 pcs)

84

**"Carbon Wafer"**

Dry Clean

Room Deburing

Equipm ent Deburr

Foil Cutting

Tool Cutting

To Size

3 1 0 1 1 1

### Page: 1 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification:

**System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)**  

## Annual Component Volume: Shipping Method:

**Component Description: Part Number:**  We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

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

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Hybrid - Start-Stop Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 2 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification:

**System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)**  

## Annual Component Volume: Shipping Method:

**Component Description: Part Number:**  We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Hybrid - Start-Stop Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### C 

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

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 3 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification:

**System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)**  

## Annual Component Volume: Shipping Method:

**Component Description: Part Number:**  We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Hybrid - Start-Stop Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

5 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

6 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to

T1 or OEM for Final or Sub

- Assembly. In addition component material cost is

accounted for in T1 quote sheet. Thus component cost will only be included for

Mark

- up Calculations.

"Alpha

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

Supplier for Subassembly. 9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

**Material**

**$0.00**

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

**Mark-up $0.00** 

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

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

----- ----- ----- ----- #N/A #N/A #N/A #N/A #N/A 

### Supplier for Subassembly.

**3 1** 



### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error. T1 or OEM Mark-Up Rates:** 

----- ----- ----- ----- #N/A #N/A #N/A #N/A #N/A

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

----- ----- ----- **#N/A #N/A**  **#N/A #N/A**  **#N/A**

**Base Cost Impact to Vehicle: $0.00**  **$0.00 $0.00**  **$0.00 #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: #N/A**  **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 4 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification:

**System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)**  

## Annual Component Volume: Shipping Method:

**Component Description: Part Number:**  We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Hybrid - Start-Stop Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment**

**(%) Total # of** 

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging**

**Cost per**

**Piece Tier Pad** 

**Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging**

**Price Per Other #1** 

**Pads**

**Pallet/Rack Other #2** 

**Packaging**

**Price Per Other #2** 

**Pads**

**Pallet/Rack Other #3** 

**Packaging,**

**Price Per Other #3** 

**Pads**

**Pallet/Rack**



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

### PACKAGING CALCULATIONS:

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers: Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote **Expendable Packaging in Piece Cost: $0.00**  $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0



### Packaging Cost Total: **$0.000** 

### Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 5 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**



## Purchase Part - High Impact Item (Full Cost Mapping) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 6 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 7 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

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

**Total**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$0.00 2** 



### Notes:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 8 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/** 

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 9 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



## Purchase Part - High Impact Item (Full Cost Mapping) **#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 10 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

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### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 11 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



## Purchase Part - Commodity ( Value taken from Purchase Part Database)**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411

### Page: 12 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level:

**Vehicle Class:**

**Study Case#:**

**System Description:**

**Component Description:**

**Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411