### Page:1 of 4 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/13/2012

DRAFT

Material Labor Burden End Item

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



### USD **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD**



# 06 **Brake Sy stem** 

1 **01 N / A** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 2 **02 N / A** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 3 **03 Front Rotor/Drum and Shield Subsystem**  **38.49 10.16**  **29.81 78.46**  **0.48 5.39**  **5.61 2.41**  **13.89**

**- 92.35** 

**- 4,988.16** 

**-**



### 4 **04 Rear Rotor/Drum and Shield Subsystem**  **44.63 11.32**  **30.51 86.46**  **0.31 5.71**  **4.01 0.86**  **10.89**

**- 97.35** 

**- 4,964.91** 

**-**



### 5 **05 Parking Brake and A**  **ctuation Subsystem 7.34**  **3.21 5.47**  **16.02 0.10**  **1.66 1.31**  **0.27 3.34** 

**- 19.36** 

**- 370.70** 

**-**



### 6 **06 Brake A**  **ctuation Subsystem 11.19**  **3.53 5.29**  **20.00 0.14**  **2.08 1.68**  **0.37 4.26** 

**- 24.26** 

**- 559.70** 

**-**



### 7 **07 Power Brake Subsystem (for Hydraulic)**  **2.94 1.05**  **2.22 6.21**  **0.04 0.66**  **0.48 0.08**  **1.26**

**- 7.47** 

**- 1,975.30** 

**-**



### 8 **08 N / A** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 9 **09 Brake Controls Subsystem (N/a)** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 10 **10 Au**  **xiliary Brake Subsystem (N/A )** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 11 **11 N / A** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** ItemSystem **System**

**ED&T/R&D**

**(x1000)** 

### Subsystem Description 

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

Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**As sembly)**  **Tooling**

**(x1000)** Markup

**Net**

**Component/**

**As sembly Cost** 

**Impact to OEM Total Markup** 

**Cost**

**(Component/**

**As sembly)**  **Total**

**Packaging**

**Cost**

**(Component/**

**As sembly)**  **Investment**

**(X1000)** 

# Technology Level: Toyota Venza Mass

- Reduction and Cost Analysis

**Vehicle Class:** Small & Mid Size Cross

- Over Passenger Vehicle

**Study Case#:** 07

- 069

- 303LW

11 **11 N / A** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 12 **12 N / A** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 13 **13 N / A** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 14 **14 N / A** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 15 **15 N / A** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 16 **16 N / A** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 104.58 **29.27 73.30**  **207.15 1.06**  **15.50 13.08**  **3.99 33.64** 

**- 240.79** 

**- 12,858.77** 

**-** 

### SYSTEM ROLL-UP

09000064810d3b0c.xls

EPA Contract:EP-C-07-069 W A1-3 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: 8/13/2012

DRAFT



# 06 **Brake Sy stem** 

1 **01 N / A** 

2 **02 N / A** 

3 **03 Front Rotor/Drum and Shield Subsystem** 

4 **04 Rear Rotor/Drum and Shield Subsystem** 

5 **05 Parking Brake and A**  **ctuation Subsystem**

6 **06 Brake A**  **ctuation Subsystem**

7 **07 Power Brake Subsystem (for Hydraulic)** 

8 **08 N / A** 

9 **09 Brake Controls Subsystem (N/a)** 

10 **10 Au**  **xiliary Brake Subsystem (N/A )** 

11 **11 N / A** ItemSystem



### Subsystem Description



# SYSTEM & SUBSYSTEM DESCRIPTION



# Technology Level: Toyota Venza Mass

- Reduction and Cost Analysis

**Vehicle Class:** Small & Mid Size Cross

- Over Passenger Vehicle

**Study Case#:** 07

- 069

- 303LW

Material Labor Burden End Item

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



### USD **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD**

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 

**49.19 10.39**  **49.94 109.53**  **0.65 7.16**  **7.54 3.39**  **18.74**

**- 128.26** 

**- 2,805.50** 

**-**

**33.71 12.26**  **56.46 102.43**  **0.35 6.49**  **4.53 1.00**  **12.37**

**- 114.79** 

**- 3,067.40** 

**-**

**45.88 19.62**  **22.20 87.69**  **0.43 7.67**  **5.52 1.03**  **14.65**

**- 102.34** 

**- 1,896.98** 

**-**

**26.04 8.26**  **11.91 46.21**  **0.31 5.01**  **3.87 0.75**  **9.93**

**- 56.13** 

**- 1,812.85** 

**-**

**2.99 1.56**  **2.86 7.42**  **0.04 0.78**  **0.52 0.07**  **1.40**

**- 8.82** 

**- 1,849.91** 

**-**

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  

# BASE TECHNOLOGY GENERAL PART INFORMATION

Markup Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**As sembly)**  **Total Markup**

**Cost**

**(Component/**

**As sembly)**  **Total**

**Packaging**

**Cost**

**(Component/**

**As sembly)**  **Net**

**Component/**

**As sembly Cost** 

**Impact to OEM System** 

**ED&T/R&D**

**(x1000) Tooling** 

**(x1000) Investment** 

**(X1000)**



### 11 **11 N / A** 

12 **12 N / A** 

13 **13 N / A** 

14 **14 N / A** 

15 **15 N / A** 

16 **16 N / A** 

**SYSTEM ROLL-UP -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 157.80 **52.09 143.38**  **353.27 1.77**  **27.10 21.98**  **6.23 57.08** 

**- 410.35** 

**- 11,432.64** 

**-**



### 09000064810d3b0c.xls

EPA Contract:EP-C-07-069 W A1-3 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: 8/13/2012

DRAFT



# 06 **Brake Sy stem** 

1 **01 N / A** 

2 **02 N / A** 

3 **03 Front Rotor/Drum and Shield Subsystem** 

4 **04 Rear Rotor/Drum and Shield Subsystem** 

5 **05 Parking Brake and A**  **ctuation Subsystem**

6 **06 Brake A**  **ctuation Subsystem**

7 **07 Power Brake Subsystem (for Hydraulic)** 

8 **08 N / A** 

9 **09 Brake Controls Subsystem (N/a)** 

10 **10 Au**  **xiliary Brake Subsystem (N/A )** 

11 **11 N / A** ItemSystem



### Subsystem Description



# SYSTEM & SUBSYSTEM DESCRIPTION



# Technology Level: Toyota Venza Mass

- Reduction and Cost Analysis

**Vehicle Class:** Small & Mid Size Cross

- Over Passenger Vehicle

**Study Case#:** 07

- 069

- 303LW

Material Labor Burden End Item

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



### USD **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**

**10.70 0.23**  **20.13 31.06**  **0.17 1.77**  **1.94 0.97**  **4.85**

**- 35.91** 

**- (2,182.66)** 

**(10.92) 0.94**  **25.95 15.96**  **0.04 0.78**  **0.52 0.14**  **1.48**

**- 17.44** 

**- (1,897.51)** 

**38.54 16.40**  **16.73 71.67**  **0.32 6.01**  **4.22 0.76**  **11.31**

**- 82.98** 

**- 1,526.28** 

**14.85 4.73**  **6.63 26.21**  **0.17 2.93**  **2.18 0.38**  **5.66**

**- 31.87** 

**- 1,253.15** 

**0.05 0.51**  **0.65 1.21**  **0.00 0.12**  **0.04 (0.02)**  **0.14**

**- 1.35** 

**- (125.39)** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**As sembly)**  Markup

**Total Markup**

**Cost**

**(Component/**

**As sembly)**  **Total**

**Packaging**

**Cost**

**(Component/**

**As sembly)**  **Net**

**Component/**

**As sembly Cost** 

**Impact to OEM System** 

**ED&T/R&D**

**(x1000) Tooling** 

**(x1000)**



### 11 **11 N / A** 

12 **12 N / A** 

13 **13 N / A** 

14 **14 N / A** 

15 **15 N / A** 

16 **16 N / A** 

**SYSTEM ROLL-UP -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**



### 53.22 **22.81 70.08**  **146.12 0.70**  **11.60 8.90**  **2.24 23.44** 

**- 169.56** 

**- (1,426.12)** 



### 09000064810d3b0c.xls

EPA Contract:EP-C-07-069 W A1-3 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: 8/13/2012

DRAFT



# 06 **Brake Sy stem** 

1 **01 N / A** 

2 **02 N / A** 

3 **03 Front Rotor/Drum and Shield Subsystem** 

4 **04 Rear Rotor/Drum and Shield Subsystem** 

5 **05 Parking Brake and A**  **ctuation Subsystem**

6 **06 Brake A**  **ctuation Subsystem**

7 **07 Power Brake Subsystem (for Hydraulic)** 

8 **08 N / A** 

9 **09 Brake Controls Subsystem (N/a)** 

10 **10 Au**  **xiliary Brake Subsystem (N/A )** 

11 **11 N / A** ItemSystem



### Subsystem Description



# SYSTEM & SUBSYSTEM DESCRIPTION



# Technology Level: Toyota Venza Mass

- Reduction and Cost Analysis

**Vehicle Class:** Small & Mid Size Cross

- Over Passenger Vehicle

**Study Case#:** 07

- 069

- 303LW

**USD**

**Part $ Tool $** 

**-**

**-**

**-** 

### 28.0% -77.8%

**-** 

### 15.2% -61.9%

**-** 

### 81.1% 80.5%

**-** 

### 56.8% 69.1%

**-** 

### 15.3% -6.8%

**-**

**-**

**-**

**- Investment** 

**(X1000)**



### 11 **11 N / A** 

12 **12 N / A** 

13 **13 N / A** 

14 **14 N / A** 

15 **15 N / A** 

16 **16 N / A** 

**SYSTEM ROLL-UP -** 

**-**

**-**

**-**

**-**

**-**

**-** 

### 41.3% -12.5%

09000064810d3b0c.xls

EPA Contract:EP-C-07-069 W A1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich

(248)373-6000 Ext. 2411