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 System

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 Actuation 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 Actuation 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 Auxiliary Brake Subsystem (N/A) - - - - - - - - - - - - - -

11 11 N / A - - - - - - - - - - - - - -

Item

System

System 

ED&T/R&D

(x1000)

Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION NEW TECHNOLOGY GENERAL PART INFORMATION

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup

Net 

Component/ 

Assembly Cost 

Impact to OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component/ 

Assembly)

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 - - - - - - - - - - - - - -

SYSTEM ROLL-UP 104.58 29.27 73.30 207.15 1.06 15.50 13.08 3.99 33.64 - 240.79 - 12,858.77 -

09000064810d3b0c.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: 8/13/2012

DRAFT

06 Brake System

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 Actuation Subsystem

6 06 Brake Actuation Subsystem

7 07 Power Brake Subsystem (for Hydraulic)

8 08 N / A

9 09 Brake Controls Subsystem (N/a)

10 10 Auxiliary Brake Subsystem (N/A)

11 11 N / A

Item

System

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

Manufacturing Total Markup

Manufacturing 

Cost 

(Component/ 

Assembly)

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)

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 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: 8/13/2012

DRAFT

06 Brake System

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 Actuation Subsystem

6 06 Brake Actuation Subsystem

7 07 Power Brake Subsystem (for Hydraulic)

8 08 N / A

9 09 Brake Controls Subsystem (N/a)

10 10 Auxiliary Brake Subsystem (N/A)

11 11 N / A

Item

System

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/ 

Assembly)

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)

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 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: 8/13/2012

DRAFT

06 Brake System

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 Actuation Subsystem

6 06 Brake Actuation Subsystem

7 07 Power Brake Subsystem (for Hydraulic)

8 08 N / A

9 09 Brake Controls Subsystem (N/a)

10 10 Auxiliary Brake Subsystem (N/A)

11 11 N / A

Item

System

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 WA1-3 PROPRIETARY and CONFIDENTIAL

Author: G. Kolwich

(248)373-6000 Ext. 2411