Page:1 of 6 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

030500 Interior Trim and Ornamentation Subsystem

1 00 Assembly of Interior Trim and Ornamentation Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 01 Main Floor Trim $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

3 02 NVH Pads $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

4 03 Headliner Assembly $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

5 04 Sun Visors $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Item

Subsystem

System 

ED&T/R&D

(x1000)

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Investment

(X1000)

BASE TECHNOLOG

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

6 05 Front Door Trim Panel $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

7 06 Rear Door or Rear Quarter Trim Panel $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 07 Pillar Trim Lower $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 08 Load Compartment Side Trim $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 09 Rear Closure Interior Trim Panel $ 4.74 $ 1.00 $ 1.03 $ 6.77 $ 0.04 $ 0.52 $ 0.48 $ 0.18 $ 1.22 $ - $ 7.99 $ - $ - $ - $ - $ - $ - $ -

11 13 Front Door Interior Frame Finisher $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 14 Rear Door Interior Frame Finisher $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 15 Cargo Retention $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 16 Floor Mats - OEM $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

15 17 Load Compartment Floor Trim $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

16 18 Cabin Rear Trim $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

17 19 Pillar Trim Upper $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

18 20 Parcel Shelf / Blinds $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

19 21 Load Compartment Transverse Trim $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

20 22 Applied Decorative Trim - Side Doors $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Item

Subsystem

System 

ED&T/R&D

(x1000)

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Investment

(X1000)

BASE TECHNOLOG

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

21 70 Pipes, Hoses, Ducting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

22 75 Brackets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

23 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

24 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SUBSYSTEM ROLL-UP $ 4.74 $ 1.00 $ 1.03 $ 6.77 $ 0.04 $ 0.52 $ 0.48 $ 0.18 $ 1.22 $ - $ 7.99 $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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: 8/23/2012

DRAFT

030500 Interior Trim and Ornamentation Subsystem

1 00

2 01

3 02

4 03

5 04

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

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

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

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

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

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

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)

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

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

6 05

7 06

8 07

9 08

10 09

11 13

12 14

13 15

14 16

15 17

16 18

17 19

18 20

19 21

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

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

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

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 4.74 $ 1.00 $ 1.03 $ 6.77 $ 0.04 $ 0.52 $ 0.48 $ 0.18 $ 1.22 $ - $ 7.99 $ - $ -

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

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

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

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

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

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

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

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

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

20 22 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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: 8/23/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

21 70

22 75

23 80

24 99

End Item 

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

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)

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

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

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

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

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

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 4.74 $ 1.00 $ 1.03 $ 6.77 $ 0.04 $ 0.52 $ 0.48 $ 0.18 $ 1.22 $ - $ 7.99 $ - $ -

09000064810ec171.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: 8/23/2012

DRAFT

030500 Interior Trim and Ornamentation Subsystem

1 00

2 01

3 02

4 03

5 04

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

$ -

$ -

$ -

$ -

$ -

Investment(X1

000)

6 05

7 06

8 07

9 08

10 09

11 13

12 14

13 15

14 16

15 17

16 18

17 19

18 20

19 21

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

20 22 $ -

09000064810ec171.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: 8/23/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

21 70

22 75

23 80

24 99

Investment(X1

000)

$ -

$ -

$ -

$ -

$ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:1 of 6 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

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

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

030500 Interior Trim and Ornamentation Subsystem

1 00 Assembly of Interior Trim and Ornamentation Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 01 Main Floor Trim $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

3 02 NVH Pads $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Sub-Subsystem

Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

System 

ED&T/R&D

(x1000)

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

3 02 NVH Pads $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

4 03 Headliner Assembly $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

5 04 Sun Visors $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

6 05 Front Door Trim Panel $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

7 06 Rear Door or Rear Quarter Trim Panel $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

8 07 Pillar Trim Lower $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 08 Load Compartment Side Trim $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 09 Rear Closure Interior Trim Panel $ 4.74 $ 1.00 $ 1.03 $ 6.77 $ 0.04 $ 0.52 $ 0.48 $ 0.18 $ 1.22 $ - $ 7.99 $ -

H Trunk Close Out Battery 03 05 09 - N0502- 00 1 Full 1 $ 4.74 $ 1.00 $ 1.03 $ 6.77 $ 0.04 $ 0.52 $ 0.48 $ 0.18 $ 1.22 $ - $ 7.99 $ -

11 13 Front Door Interior Frame Finisher $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 14 Rear Door Interior Frame Finisher Rear Door Interior Frame Finisher $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ -

09000064810ec171.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: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

Sub-Subsystem

Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

System 

ED&T/R&D

(x1000)

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

13 15 Cargo Retention $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 16 Floor Mats - OEM $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

15 17 Load Compartment Floor Trim $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

16 18 Cabin Rear Trim $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

17 19 Pillar Trim Upper $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

18 20 Parcel Shelf / Blinds $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

19 21 Load Compartment Transverse Trim $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

20 22 Applied Decorative Trim - Side Doors $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

21 70 Pipes, Hoses, Ducting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

22 75 Brackets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

23 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

23 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

23 90 Bearings Elements Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

24 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

09000064810ec171.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: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

Sub-Subsystem

Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

System 

ED&T/R&D

(x1000)

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

$ 4.74 $ 1.00 $ 1.03 $ 6.77 $ 0.04 $ 0.52 $ 0.48 $ 0.18 $ 1.22 $ - $ 7.99 $ -

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) No

09000064810ec171.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: 8/23/2012

DRAFT

0

030500 Interior Trim and Ornamentation Subsystem

1 00 Assembly of Interior Trim and Ornamentation Subsystem

2 01 Main Floor Trim

3 02 NVH Pads

Sub-Subsystem

Part Number

QTY/ Subsystem

Notes

Subassembly

Component

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

3 02 NVH Pads

4 03 Headliner Assembly

5 04 Sun Visors

6 05 Front Door Trim Panel

7 06 Rear Door or Rear Quarter Trim Panel

8 07 Pillar Trim Lower

9 08 Load Compartment Side Trim

10 09 Rear Closure Interior Trim Panel

H Trunk Close Out Battery 03 05 09 - N0502- 00 1 Full 1

11 13 Front Door Interior Frame Finisher

12 14 Rear Door Interior Frame Finisher

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

12 14 Rear Door Interior Frame Finisher $ $ - $ $ -

09000064810ec171.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: 8/23/2012

DRAFT

Sub-Subsystem

Part Number

QTY/ Subsystem

Notes

Subassembly

Component

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

13 15 Cargo Retention

14 16 Floor Mats - OEM

15 17 Load Compartment Floor Trim

16 18 Cabin Rear Trim

Investment

(X1000)

Tooling 

(x1000)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

17 19 Pillar Trim Upper

18 20 Parcel Shelf / Blinds

19 21 Load Compartment Transverse Trim

20 22 Applied Decorative Trim - Side Doors

21 70 Pipes, Hoses, Ducting

22 75 Brackets

23 80 Boltings

23 85 Sealing Elements

23 90 Bearings Elements Misc

24 99 Miscellaneous

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

09000064810ec171.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: 8/23/2012

DRAFT

Sub-Subsystem

Part Number

QTY/ Subsystem

Notes

Subassembly

Component

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

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) No

Investment

(X1000)

Tooling 

(x1000)

$ - $ -

09000064810ec171.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: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

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

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

030500 Interior Trim and Ornamentation Subsystem

1 00 Assembly of Interior Trim and Ornamentation Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 01 Main Floor Trim $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

3 02 NVH Pads $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

4 03 Headliner Assembly $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

5 04 Sun Visors $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

6 05 Front Door Trim Panel $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

7 06 Rear Door or Rear Quarter Trim Panel $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 07 Pillar Trim Lower $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 08 Load Compartment Side Trim $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 09 Rear Closure Interior Trim Panel $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 13 Front Door Interior Frame Finisher $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 14 Rear Door Interior Frame Finisher $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 15 Cargo Retention $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

14 16 Floor Mats - OEM $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

15 17 Load Compartment Floor Trim $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

16 18 Cabin Rear Trim $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

17 19 Pillar Trim Upper $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

18 20 Parcel Shelf / Blinds $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

19 21 Load Compartment Transverse Trim $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

20 22 Applied Decorative Trim - Side Doors $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

21 70 Pipes, Hoses, Ducting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

22 75 Brackets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

23 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

24 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

NOTES:

Complete Subsystem Quote 

(Yes/No) N

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

09000064810ec171.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: 8/23/2012

DRAFT

0

030500 Interior Trim and Ornamentation Subsystem

1 00 Assembly of Interior Trim and Ornamentation Subsystem

2 01 Main Floor Trim

3 02 NVH Pads

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

4 03 Headliner Assembly

5 04 Sun Visors

6 05 Front Door Trim Panel

7 06 Rear Door or Rear Quarter Trim Panel

8 07 Pillar Trim Lower

9 08 Load Compartment Side Trim

10 09 Rear Closure Interior Trim Panel

11 13 Front Door Interior Frame Finisher

12 14 Rear Door Interior Frame Finisher

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

13 15 Cargo Retention $ - $ -

09000064810ec171.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: 8/23/2012

DRAFT

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

14 16 Floor Mats - OEM

15 17 Load Compartment Floor Trim

16 18 Cabin Rear Trim

17 19 Pillar Trim Upper

Investment

(X1000)

Tooling 

(x1000)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

18 20 Parcel Shelf / Blinds

19 21 Load Compartment Transverse Trim

20 22 Applied Decorative Trim - Side Doors

21 70 Pipes, Hoses, Ducting

22 75 Brackets

23 80 Boltings

24 99 Miscellaneous

NOTES:

Complete Subsystem Quote 

(Yes/No) N

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

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

09000064810ec171.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:8/23/2012

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#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: H Trunk Close Out Battery Part Number: 0310509-N05020-00 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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 H Trunk Close Out Battery: Push Pins 0310509-N05020-00-01 1

Assemble Trunk Close Out with 

Push Pins to vehicle body

OEM Assembly, Mark-up 

Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 122 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.63 $0.25 $0.88 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.88 $0.88 $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

Costs Broken Out In

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

Power-Split HEV 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 H Trunk Close Out Battery 0310509-N05020-00-02 1 Waterjet cut insulator T2/T3 CNC Milling, SSLC Not Applicable CNC Operator CNC Machining, LC 267 1 2 1 0.000 $0.00 $36.98 $30.38 $60.76 $0.00 $0.14 $0.23 $0.37 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.40 $0.40 $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 H Trunk Close Out Battery H Trunk Close Out Battery 0310509-N05020-00-03 0310509-N05020-00-03 1 Thermoform Thermoform T2/T3 Stamp/Form, MSMC T2/T3 Stamp/Form, MSMC Not Applicable Not Applicable Mold/Cast/Sinter Operator Mold/Cast/Sinter Operator Pres./Vac. Form, SMS Pres./Vac. Form, SMS 180 1 1 1 0.000 $0.00 $41.48 $100.00 $100.00 $100.00 $100.00 $0.00 $0.23 $0.56 $0.79 0.50% 6.50% 6.00% 1.00% 14.00% $0.11 $0.90 $0.90 $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

File:09000064810ec171.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:8/23/2012

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#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: H Trunk Close Out Battery Part Number: 0310509-N05020-00 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Power-Split HEV 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)

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

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

File:09000064810ec171.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:8/23/2012

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#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: H Trunk Close Out Battery Part Number: 0310509-N05020-00 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Power-Split HEV 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)

1 H Trunk Close Out Battery, Material 0310509-N05020-00-04 1 S $0.00 $4.62 $0.00 $4.62 $4.62

2 0 $0.00 $0.00 $0.00 $0.00 $0.00

3 H Push Pin Trunk Battery Trim 0310509-N05020-00-05 4 S $0.00 $0.03 $0.00 $0.12 $0.12

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

"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.

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

$4.74

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

Mark-up $6.92

T1 or OEM Total Manufacturing Cost: $4.74 $1.00 $1.03 $6.77 $0.01 $0.07 $0.06 $0.01 $0.15 $6.92

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.03 $0.45 $0.42 $0.17 $1.07

Base Cost Impact to Vehicle: $4.74 $1.00 $1.03 $6.77 $0.04 $0.52 $0.48 $0.18 $1.22 $7.99 $0 $0

3

1

Notes: 

a) Items 1,2, & 3 must a

Base Cost Impact to Vehicle: $4.74 $1.00 $1.03 $6.77 $0.04 $0.52 $0.48 $0.18 $1.22 $7.99 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $7.99

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

File:09000064810ec171.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:8/23/2012

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#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: H Trunk Close Out Battery Part Number: 0310509-N05020-00 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Power-Split HEV 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:09000064810ec171.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:8/23/2012

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)

H Trunk Close Out Battery: Push Pins 0310509-N05020-00-01

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

$0.63 $0.25 $0.88 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble Trunk Close Out w/ Push Pins (4x) to vehicle body 5 2 10 100 47 4700 96 37.60 85% 113 31.96 67 1 1 59 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

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)

H Trunk Close Out Battery 0310509-N05020-00-02

H Trunk Close Out Battery 0310509-N05020-00-03

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.14 $0.23 $0.37 $0.00 $0.02 $0.01 $0.00 $0.04 CNC Waterjet cutting machine create outline of Insulation, Rear Seat Pan, operator cycle & load / unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 27 1 1 27 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

H Trunk Close Out Battery 0310509-N05020-00-03 $0.23 $0.56 $0.79 $0.00 $0.05 $0.05 $0.01 $0.11 55-150 Ton Injection Molding w/ 14 cavity mold for Push Clip, Insulation; operator cycle controls 55-150 Ton Injection Molding w/ 14 cavity mold for Push Clip, Insulation; operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 20 1 1 20 1.0 1.0

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

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

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

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

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

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

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

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

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

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

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

File:09000064810ec171.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:8/23/2012

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! 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

File:09000064810ec171.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:8/23/2012

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.

H Trunk Close Out Battery, Material 0310509-N05020-00-04

H Push Pin Trunk Battery Trim 0310509-N05020-00-05

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

$4.62

$0.00

$0.12

$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

$1.00 $1.03 $6.77 $0.01 $0.07 $0.06 $0.01 $0.15

$6.92

2

Notes: 

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

File:09000064810ec171.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:8/23/2012

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:09000064810ec171.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:8/23/2012

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)

H Trunk Close Out Battery: Push Pins 0310509-N05020-00-01

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

122 29.50 2.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

H Trunk Close Out Battery 0310509-N05020-00-02

H Trunk Close Out Battery 0310509-N05020-00-03

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

267 13.50 1.00

#DIV/0! #DIV/0! -

H Trunk Close Out Battery 0310509-N05020-00-03 180 20.00 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! -

File:09000064810ec171.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:8/23/2012

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! -

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! -

File:09000064810ec171.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:8/23/2012

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.

H Trunk Close Out Battery, Material 0310509-N05020-00-04

H Push Pin Trunk Battery Trim 0310509-N05020-00-05

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.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:8/23/2012

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:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
14 3 H Interior Trim and Ornamentation SubsyQTYstem $$$

o H Trunk Close Out Battery Asm 1

o H Trunk Close Out Battery, Molded 1

o H Push Pin Trunk Bat trim 4







6 0
Comments

PMAP

PMAP

Commodity
Indented Bill of Materials

Interior Trim and Ornamentation Subsystem

Level Symbol Name Number Qty Material Piece Cost Weight Piece Cost Weight (Tot

(Total)

0

H Trunk Close Out Battery H Trunk Close Out 1Burloom - Moldable $4.62 1.8600 lb # Battery

1 H Trunk Close Out Battery, H Trunk Close Out 1 Burloom - Moldable $4.62 1.8600 lb #

Molded Battery, Molded

2 H Trunk Close Out Battery, Material H Trunk Close Out 1 Burloom - Moldable $4.62 1.8600 lb #

Battery, Material

0 H Push Pin Trunk Bat trim H Push Pin Trunk 4 Commodity Pricing $0.03 0.0000 lb ##

Bat trim

Assembly Totals Report Totals Preassembled Totals

Analyzed Subs: 2 Piece Cost (Total): Analyzed Subs: 0

Unanalyzed Subs: 0 Unanalyzed Subs: 0

Weight (Total): 1.8600 lb

Parts: 5 Parts: 0

Fasteners: 4 Fasteners:0

Parts+Unanalyzed: 5 Parts+Unanalyzed: 0

Design Profit®

Page 1 of 1
Copyright 2010 © Design Profit, Inc.
Weight (Total)

1.8600 lb

1.8600 lb

1.8600 lb

0.0000 lb

Assembly Report

Interior Trim and Ornamentation Subsystem

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$83.31 Tool Interior Trim and First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Ornamentation 

Subsystem

- - - Close Out added to hide battery - - - - - -

$44.85 Subassembly Interior Trim and H Trunk Close Out Battery H Trunk Close Out 15.0000 sec 15.0000 sec - $0.35 1

Ornamentation Battery

Subsystem

$44.85 Tool H Trunk Close Out Waterjet 0.0000 sec 0.0000 sec $0.00 $0.00 1

Battery

$43.52 Subassembly H Trunk Close Out H Trunk Close Out Battery, H Trunk Close Out 15.0000 sec 15.0000 sec - $0.19 1

Battery Molded Battery, Molded

$43.52 Tool H Trunk Close Out Thermoform Machine 0.0000 sec 0.0000 sec $0.00 $0.00 1

Battery, Molded

$43.52 Part H Trunk Close Out H Trunk Close Out Battery, H Trunk Close Out 0.0000 sec 0.0000 sec $4.62 $0.00 1

Battery, Molded Material Battery, Material

- - - Material Sheet Required: 42" x - - - - - -

38"

$43.52 Fastening Fastening H Trunk Close Out Thermoform - Large Part Thermoform - Large Part 20.0000 sec 20.0000 sec 20.0000 sec 20.0000 sec $0.00 $0.24 1

Battery, Molded

$44.85 Fastening H Trunk Close Out Waterjet, Rubber/Foam < 1" 12.2340 sec 12.2340 sec $0.00 $0.15 1

Battery

- - - Push pins not available - - - - - -

$83.31 Part Interior Trim and H Push Pin Trunk Bat trim H Push Pin Trunk 10.0000 sec 10.0000 sec $0.03 $0.23 4

Ornamentation Bat trim

Subsystem

$83.31 Fastening Interior Trim and Press Together 3.0000 sec 3.0000 sec $0.00 $0.07 4

Ornamentation 

Subsystem

Report Totals Count: 13

16

Design Profit ®

Page 1 of 1

Copyright 2010 © Design Profit, Inc.
Piece Co

(Total)

$0.00

-

-

$0.00

-

$0.00

$4.62

-

$0.00

$0.00

-

$0.12

$0.00

$4.74
Page: 1 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

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#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: H Seating Subsystem Part Number: 020200-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

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

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

Parallel HEV 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)

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

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

File:09000064810ec171.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:8/23/2012

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#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: H Seating Subsystem Part Number: 020200-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Parallel HEV 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)

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

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 "S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubFile:09000064810ec171.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:8/23/2012

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#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: H Seating Subsystem Part Number: 020200-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Parallel HEV 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)

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

"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.

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: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

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

Base Cost Impact to Vehicle: $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $0.00

3

1

Notes: 

a) Items 1,2, & 3 must a

Net Cost Impact to Vehicle: $0.00

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

File:09000064810ec171.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:8/23/2012

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#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh) Annual Component Volume: Shipping Method:

Component Description: H Seating Subsystem Part Number: 020200-N0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Parallel HEV 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)

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:09000064810ec171.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:8/23/2012

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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

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! #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:09000064810ec171.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:8/23/2012

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! 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

File:09000064810ec171.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:8/23/2012

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

$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:09000064810ec171.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:8/23/2012

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:09000064810ec171.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:8/23/2012

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! -

#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:09000064810ec171.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:8/23/2012

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! -

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! -

File:09000064810ec171.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:8/23/2012

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:09000064810ec171.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:8/23/2012

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:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411