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 Subsystem

1 00 Assembly of High Voltage Traction Battery Subsystem $ 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 $ - $ - $ - $ - $ - $ - $ -

3 03 Power Cabling > 12V Dc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

4 70 Pipes, Hoses, Ducting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

BASE TECHNOLO

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)

Item

Subsystem

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

7 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

9 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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

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

0 0 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: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 TECHNOLO

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)

Item

Subsystem

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)

SUBSYSTEM ROLL-UP $443.84 $ 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: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 Subsystem

1 00

2 01

3 03

4 70

5 75

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 0.53 $ 2.27 $ 0.60 $ 3.40 $ - $ - $ - $ - $ - $ - $ 3.40 $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 443.31 $ 46.80 $ 181.11 $ 671.22 $ 4.85 $ 49.11 $ 55.56 $ 27.19 $ 136.71 $ 2.33 $ 810.26 $ - $ -

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

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

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

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

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:4 of 6 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/21/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

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 Subsystem

1 00

2 01

3 03

4 70

5 75

Item

Subsystem

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

DRAFT

Item

Subsystem

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 Subsystem

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)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-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 Wire 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 Wire Harness Ass'y Shielding Ground14 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)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-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 Subsystem

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)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-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 Wire 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 Wire Harness Ass'y Shielding Ground14 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)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-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 Subsystem

1 00 Assembly of High Voltage Traction Battery Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

2 01 Traction Battery $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

3 03 Power Cabling > 12V Dc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

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 Subsystem

1 00 Assembly of High Voltage Traction Battery Subsystem

2 01 Traction Battery

3 03 Power Cabling > 12V Dc

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification: Not Applicable

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

1 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 RATES MANUFACTURING COSTS

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification: Not Applicable

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

File: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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification: Not Applicable

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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

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

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

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 a

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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification: Not Applicable

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

PACKAGING 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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.70 $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 Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

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

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! #DIV/0! 85% 0 #DIV/0! #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

File: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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.24

$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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

File: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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File: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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 Assembly 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

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-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 Wrapper - 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 Warning # 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

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-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 WH # 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 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 WH # 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 Wrap # 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 Assembly 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

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-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 Wrapper - 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 Warning # 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

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-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 WH # 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 WH # 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 Wrap # 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 Type 1 $ 895.35 $392.14
2) Battery Type 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 System

Level Symbol Name Number Qty Material Piece Cost Weight Piece Cost Weight (Total)

. (Total)

.

V Battery Subsystem V Battery 56.7351 lb

.

Subsystem

. 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 Weld Nut - Projection v Weld 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 - BatteryV Bracket #2 - Tray 1 Steel Low $0.00 0.9024 lb $0.00

. Battery Tray Carbon Draw 

. Quality

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

. Battery Tray Carbon Draw 

. Quality

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

. Battery Tray Carbon Draw 

. Quality

. 4 v Weld Nut - Projection v Weld Nut - 3 $0.00 0.0028 lb

. Projection

. 3 V Hinge Bracket - Access Door V Hinge Bracket 2 Steel Low $0.00 0.0750 lb

. - Access 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 - Weld Stud V Bracket - Weld 1 Steel Low $0.00 0.0348 lb

. Stud Carbon Draw 

. Quality
.

3 V Weld Stud V Weld Stud1 Commodity $0.00 0.0092 lb

. Pricing . 2 V Bracket #3 - BatteryV Bracket #3 - Tray 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 TrayV 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 - Weld Stud V Bracket - Weld 1 Steel Low $0.00 0.0348 lb . Stud Carbon Draw . Quality . 3 V Weld Stud V Weld Stud 1 Commodity $0.00 0.0092 lb . Pricing . 2 V Bracket #4- Battery V Bracket #4- Battery Tray V Bracket #4- V Bracket #4- 1 $0.00 0.2130 lb 0.2130 lb $0.00 . Battery Tray . 3 V Bracket #4- Battery TrayV Bracket #4- 1 $0.00 0.2130 lb . Battery Tray . 2 V Bracket # 5- BatteryV Bracket # 5- Tray 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 TrayV 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 - Weld Stud V Bracket - Weld 1 Steel Low $0.00 0.0348 lb

. Stud Carbon Draw 

. Quality

. 3 V Weld Stud V Weld Stud 1 Commodity $0.00 0.0092 lb

. Pricing

. 2 V Bracket #6 - BatteryV Bracket #6 - Tray 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 TrayV Bracket #6 - 1 Steel Low $0.00 1.0000 lb

. Battery Tray Carbon Draw 

. Quality

. 3 v Weld Nut - Projection v Weld 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 V Chassis - Battery Disconn Unit Disconn Unit V Chassis - V Chassis - 1 ABS $0.00 0.7500 lb 0.7500 lb $0.00

. 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 - Auto Batt. Discharge V Module - Auto 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

. BAttery . 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 AV ssembly

1 $0.00 1.9828 lb $0.00

. Harness- . Battery Pack . Assembly . 2 V Harness-Battery Pack A V ssembly

1 $0.00 0.8450 lb $0.00

. Harness- . Battery Pack . Assembly . 2 V Harness Batt. Pack Signal V Harness Batt. 

1 $0.00 0.4650 lb $0.00

. Pack Signal . 2 V Harness- Interface V Harness1 $0.00 0.4300 lb $0.00 . Interface . 2 V Battery Control PCB AV Battery ssembly 1 $0.00 0.2428 lb $0.00 . Control PCB . Assembly . 1 V Screw-Batt. Disconn SWV Screw-Batt. Assy 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 - NMHV Battery 3 Nickel Metal $0.00 12.8451 lb $0.00 . Module - NMH Hydride
.

. 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 Polypropylene $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 FloorV Battery Cell 1 PPE PS 10 GF $0.00 0.0000 lb

. Case Floor

. 2 V Separator - Battery Chassis V Separator - 2 Aluminum $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 TempV 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 - Battery module - tray V Screw - V Screw - 12 $0.00 0.0033 lb 0.0033 lb $0.00

. Battery module - 

. tray

. 1 V Cable-Positive BatteryV Short 1 Copper $0.00 0.2250 lb $0.00

. Cable-Positive 

. Battery 3-6

. 1 V Cable-Positive BatteryV 1-4 1 Copper $0.00 0.2250 lb $0.00

. Cable-Positive 

. Battery 1-4

. 1 V Cable-Positive BatteryV 2-Service Terminal 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 Wrap V Tie Wrap 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 Weld Nut - Projection v Weld Nut - 4 $0.00 0.0028 lb

. Projection

. 3 V Weld Nut - Projection Large V Weld 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 Recyclev Label - NiMH 1 Polyethylene $0.00 0.0013 lb $0.00

. Recycle

. 2 V Clip - Rosebud WH V Clip - Rosebud 1 Polypropylene $0.00 0.0022 lb $0.00

. WH

. 1 V Screw - Battery Pack LidV 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 FanV Housing - 1 $0.00 0.4413 lb $0.00

. Battery Fan

. 3 V Housing - Battery FanV 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 Assy - Batt. Cooling V Fan Assy - 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 Stator V Shaft - Motor V Shaft - Motor 1 Brass # 0.0183 lb 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 V Stator ssy 1 Commodity $0.00 0.0669 lb

. Windings - Batt. Prcing

. Fan Assy

. 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 Warning V Label - Batt. 1 Polyethylene $0.00 0.0013 lb $0.00

. Fan Warning

. 2 V Seal - BAtt. Fan - CaseV 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 0.2130 lb 14 03 75 A5 14 03 75 - N0402 - 21 V Tray - Battery - Battery 0375A

$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 0.7500 lb 14 03 03 A1 14 03 03 - N0402 - 02 V Battery V Battery Disconnect Unit 0303A 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 0.0396 lb 14 03 80 F 14 03 80 - N0402 - 18 V Battery V Battery Module - NMH 0303C 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 0.0183 lb 14 03 80 A2 14 03 80 - N0402 - 27

# 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 (Weeks/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 Weekly Component Volume: Packagi

Component Quote Level: Estimated Product Life:

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

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 RATES MANUFACTURING COSTS

Mild Series Gasoline Hybrid

MARK-UP 

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

Full Quote Modification Quote

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

8 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 (Weeks/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 Weekly Component Volume: Packagi

Component Quote Level: Estimated Product Life:

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

9,574

10

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Series Gasoline Hybrid

MARK-UP 

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

Full Quote Modification Quote

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

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

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:

Reference #

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 

Markup 

Rate

Total 

Mark-up 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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 Weld, 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 Injection 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 Injection 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

MARK-UP COSTS Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information

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 Injection 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 Injection 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 Injection 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 Injection 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 Injection 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 Weld / 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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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 

Markup 

Rate

Total 

Mark-up 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

North America

North America

FOB Ship Point

MARK-UP COSTS Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information

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

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

V Foil Applique - Battery Top 140399-N0402-10

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification: N/A Considered WIP (work in progress)

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

1 1A 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 RATES MANUFACTURING COSTS

North America

North America

FOB Ship Point

47

450,000

1

Mild Series Gasoline Hybrid

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification: N/A Considered WIP (work in progress)

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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 RATES MANUFACTURING COSTS

North America

North America

FOB Ship Point

47

450,000

1

Mild Series Gasoline Hybrid

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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

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 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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification: N/A Considered WIP (work in progress)

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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 RATES MANUFACTURING COSTS

North America

North America

FOB Ship Point

47

450,000

1

Mild Series Gasoline Hybrid

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

13 0 ##### 0 1 1 0.00000 #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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

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

Supplier for Subassembly.

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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification: N/A Considered WIP (work in progress)

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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 RATES MANUFACTURING COSTS

North America

North America

FOB Ship Point

47

450,000

1

Mild Series Gasoline Hybrid

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

27 0 $0.00 $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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

Packaging Cost Total: $0.000

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Takt Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Takt Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Takt Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.44 $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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Takt Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

$0.00

$0.00

$0.00

$0.00

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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 (Weeks/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 Weekly Component Volume: Packag

Component Quote Level: Estimated Product Life:

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

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 RATES MANUFACTURING COSTS

Mild Series Gasoline Hybrid

MARK-UP 

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 Quote

Differential Quote (Quote Summary includes costing for both Technology 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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

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 (Weeks/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 Weekly Component Volume: Packag

Component Quote Level: Estimated Product Life:

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Series Gasoline Hybrid

MARK-UP 

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 Quote

Differential Quote (Quote Summary includes costing for both Technology 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:

Reference #

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 

Markup 

Rate

Total 

Mark-up 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

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

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

MARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Projected Operating 

MANUFACTURING ASSUMP

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

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

$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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Markup 

Rate

Total 

Mark-up 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

MARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Projected Operating 

MANUFACTURING ASSUMP

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:

Reference #

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.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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

Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

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 RATES MANUFACTURING COSTS

Mild Series Gasoline Hybrid

MARK-UP COSTS TOTAL COSTS TOOLING & INVESTM

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

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

5 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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

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

Supplier for Subassembly.

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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Series Gasoline Hybrid

MARK-UP COSTS TOTAL COSTS TOOLING & INVESTM

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

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

Base Cost Impact to Vehicle: $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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for 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)

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

Packaging Cost Total: $0.000

Number of Layers: Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

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

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

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

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

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File: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:

Reference #

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.

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

$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 Gross Mark-up Costs x Quantity Process Information

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

Power Connector - Thru Hole WM3809-ND $1.41 $1.41

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information

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:

Reference #

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.

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

 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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/Year): OEM Plan

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plan

Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Cla

System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid) Annual Component Volume: Shippin

Component Description: V Battery Disconnect Unit, Traction Battery Assembly Part Number: 140301-N0402-01 Weekly Component Volume: Packaging Sp

Component Quote Level: Estimated Product Life:

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

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 RATES MANUFACTURING COSTS

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

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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

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

Supplier for Subassembly.

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 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 (Weeks/Year): OEM Plan

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plan

Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Cla

System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid) Annual Component Volume: Shippin

Component Description: V Battery Disconnect Unit, Traction Battery Assembly Part Number: 140301-N0402-01 Weekly Component Volume: Packaging Sp

Component Quote Level: Estimated Product Life:

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

9,574

10

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

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

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:

Reference #

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

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

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 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

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

MARK-UP COSTS Projected Operating Pattern Minimum Calculated Cycles Tim

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information

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.

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

North America

North America

FOB Ship Point

MARK-UP COSTS Projected Operating Pattern Minimum Calculated Cycles Tim

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information

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:

Reference #

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.

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

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

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

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

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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

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

Supplier for Subassembly.

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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

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

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

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for 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)

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

Packaging Cost Total: $0.000

Number of Layers: Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

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

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

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

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

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File: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:

Reference #

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.

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

TOOLING & INVESTMENT Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Proce

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

TOOLING & INVESTMENT Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Proce

$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:

Reference #

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.

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

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 RATES MANUFACTURING COSTS

Mild Series Gasoline Hybrid

MARK-UP COSTS TOTAL COSTS TOOLING & INVESTMEN

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

Full Quote Modification Quote

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

9 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 SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 

or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

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

Supplier for Subassembly.

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for 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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Series Gasoline Hybrid

MARK-UP COSTS TOTAL COSTS TOOLING & INVESTMEN

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

Full Quote Modification Quote

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

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

Packaging Cost Total: $0.000

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:

Reference #

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.

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

$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 Wash / 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 Injection 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 Gross Mark-up Costs x Quantity Process Information Project Process Req

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 Injection 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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Req

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:

Reference #

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.

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/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 Weekly Component Volume:

Component Quote Level: Estimated Product Life:

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

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 RATES MANUFACTURING COSTS

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 Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology 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 SubAssembly.

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

to T1 or OEM for Final or Sub-Assembly. In addition component material cost 

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

for Mark-up Calculations.

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 (Weeks/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 Weekly Component Volume:

Component Quote Level: Estimated Product Life:

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

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

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

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:

Reference #

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 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

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

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

MARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Projected Operating Pattern

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

1 $10.85 $10.85

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

MARK-UP COSTS TOTAL COSTS TOOLING & INVESTMENT Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity

North America

North America

FOB Ship Point

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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:

Reference #

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.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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

Minimum Calculated Cycles Time Project Process Requirement

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

MANUFACTURING ASSUMPTIONS

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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

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, Base257 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

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

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

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 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

Number of Parts per Pallet/Supplier, Customer and InSupplier, Customer and InPACKAGING 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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

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

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 Quote Differential Quote (Quote Summary includes costing for both Technology 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:

Reference #

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.

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

$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 Wash / 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 Weld, 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

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

TOOLING & INVESTMENT Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Pr

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

TOOLING & INVESTMENT Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Pr

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:

Reference #

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.

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

 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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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

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

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 Quote

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

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

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

Cost per Pallet /Rack

Total Number of Pallets/

Number of Parts per Pallet/Supplier, Customer and InRequirements (Weeks)Supplier, Customer and InRequirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

Packaging Cost Total: $0.000

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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier Classification Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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

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 Quote

Differential Quote (Quote Summary includes costing for both Technology 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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

$0.00 $0.17 $0.51 $0.68 $0.00 $0.04 $0.03 $0.00 $0.07 Wash / Paint / Bake / Cure Service Door Weldment 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 Weld, 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

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

Purchase Part - 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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

File: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:

Reference #

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.

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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 - Wash & 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 Weldment 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 Weldment 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 RATES MANUFACTURING COSTS

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 Quote Differential Quote (Quote Summary includes costing for both Technology 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 Weldment 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 - Weld 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 Weldment 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 - Weld 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 Weldment 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 - Weld 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 Weldment 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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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 Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process Description OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

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

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging Other #1 Other #1 Other #2 Other #2 Other #3 Other #3 

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for 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:

Reference #

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 - Wash & Paint 140375-N0402-01

V Tray - Battery Assembly - Final Weldment 140375-N0402-01

V Tray - Battery Weldment 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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

$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 Wash / Paint / Bake / Cure Final Weldment 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 Weld, 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 Weld, 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 Gross Mark-up Costs x Quantity Process Information Project Process Requ

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 Weldment 140375-N0402-07

V Bracket #2 - Battery Tray Stamping 140375-N0402-09

V Hinge Bracket - Access Door, Brkt #2 140375-N0402-10

V Bracket - Weld Stud, Brkt #2 140375-N0402-12

V Bracket #3 - Battery Tray Weldment 140375-N0402-14

V Bracket #3 - Battery Tray Stamping 140375-N0402-15

V Bracket - Stand Off, Brkt #3 140375-N0402-17

V Bracket - Weld Stud, Brkt #3 140375-N0402-19

V Bracket #4- Battery Tray Stamping 140375-N0402-21

V Bracket #5 - Battery Tray Weldment 140375-N0402-23

V Bracket #5 - Battery Tray Stamping 140375-N0402-24

V Bracket - Stand Off, Brkt #5 140375-N0402-26

V Bracket - Weld Stud, Brkt #5 140375-N0402-28

V Bracket #6 - Battery Tray Weldment 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 Weld, 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 Weld, 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 Weld, 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 Weld, 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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requ

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:

Reference #

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 - Wash & Paint 140375-N0402-01

V Tray - Battery Assembly - Final Weldment 140375-N0402-01

V Tray - Battery Weldment 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.

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 Weldment 140375-N0402-07

V Bracket #2 - Battery Tray Stamping 140375-N0402-09

V Hinge Bracket - Access Door, Brkt #2 140375-N0402-10

V Bracket - Weld Stud, Brkt #2 140375-N0402-12

V Bracket #3 - Battery Tray Weldment 140375-N0402-14

V Bracket #3 - Battery Tray Stamping 140375-N0402-15

V Bracket - Stand Off, Brkt #3 140375-N0402-17

V Bracket - Weld Stud, Brkt #3 140375-N0402-19

V Bracket #4- Battery Tray Stamping 140375-N0402-21

V Bracket #5 - Battery Tray Weldment 140375-N0402-23

V Bracket #5 - Battery Tray Stamping 140375-N0402-24

V Bracket - Stand Off, Brkt #5 140375-N0402-26

V Bracket - Weld Stud, Brkt #5 140375-N0402-28

V Bracket #6 - Battery Tray Weldment 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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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
Anode 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 Hydroxide) 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 volume 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 Welder 3.0000

Separator Assy

$29.69 Fastening V Electrode and Seam Weld 0.0000

Separator Assy

$43.52 Operation V Battery Cell Insert Electrode Stack 1.0000

Case

$43.52 Tool V Battery Cell Projection Welder 3.0000

Case

$43.52 Fastening V Battery Cell Projection Weld 20.0000

Case

$43.52 Tool V Battery Cell Heat Weld Tool 2.0000

Case

$43.52 Fastening V Battery Cell Heat Weld 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 Weld

Potasium 

Hydroxide 7.0000

$0.00 Fastening Electrolyte - Heat Weld 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 Weight=.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 Weight=.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 Wrap V Tie Wrap 

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 Wire 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 Width Thickness Weight/pc

cm3 g/cm3 (grams)

Cathode (+) Aluminum 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 Walls

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

Electrolyte - Potasium Hydroxide

V Sensor - Battery Temp

v Label - Part No. Manuf.

V Screw Terminal Post Bracket - Battery

V Screw - Battery module - tray

V Tie Wrap

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 PLATE MANUFACTURING CELL CONFIGURATIONS

28-Jan-09

Cell Electrode Wrapper 450K/yr x 60 wrappers/battery = 27.0M wrappers/yr "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)

Clamp

Insert 

Electrode 

Stack 

Separator

Seam

Welder

Cycle Time 70 56 84 56 0 2 1 0

Supplier

Est. Cost

Voltage

Amperage

Watts

Air

Other

Electrode Plate Positive 450K/yr x 840 plates/battery = 378.0M (+) plates/yr

Electrode Plate Negative 450K/yr x 840 plates/battery = 378.0M (-) plates/yr "Carbon Wafer"

Operation

Slurry - 

Cathode/

Anode

Mix 

Slurrry

Electrode 

Foil Rollers Coat Appilcation 

Electrode 

Knife 

Compres

s Foil Oven

Cycle Time 0 1 4 1 1 1 1 6

Supplier

Est. Cost

Voltage

Amperage

Watts

Air

Other

Electrolyte - Potassium Hydroxide 450K/yr x 6 cells/battery = 2.7M cells/yr

Operation

Move 

Battery to 

Dry Room

Heat Dry

Battery

Move to 

Vaccum Fill 

Equipment

Vaccum 

Fill 

Electrolyte

Move to 

Heat Weld

Heat 

Weld 

Seams

Cycle Time 60 3600 5 10 3 20

Supplier

Est. Cost

Voltage

Amperage

Watts

Air

Other
"Accordion Stack"

Seam

Weld 

Electrode 

Tabs 

(28 pcs)

84

"Carbon Wafer"

Dry Clean 

Room 

Deburing 

Equipment

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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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: Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

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

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

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

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

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

Costs Broken Out In

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

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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: Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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: Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 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 SubAssembly.

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

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

Mark-up Calculations.

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

Supplier for Subassembly. 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: 

T1 or OEM Mark-Up Rates: a) Items 1,2, & 3 must a----- ----- ----- ----- #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 a

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 (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: 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: Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic 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:

Reference #

Part Description Part Number

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

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

Purchase Part - High Impact Item (Full Cost Mapping)

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

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

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! #DIV/0! 85% 0 #DIV/0! #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

File: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:

Reference #

Part Description Part Number

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

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411