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

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

120301 Refrigeration/Air Conditioning Subsystem - AC Compressor

1 G AC Pump Assembly $ 0.50 $ 0.29 $ 1.05 $ 1.84 $ 0.01 $ 0.21 $ 0.17 $ 0.06 $ 0.46 $ - $ 2.30 $ -

A G - AC Pump Assembly (Includes items listed below) # 03 01 - B0602 - 001 1 Full 1 $ 0.50 $ 0.29 $ 1.05 $ 1.84 $ 0.01 $ 0.21 $ 0.17 $ 0.06 $ 0.46 $ - $ 2.30 $ -

G Snap-ring, AC Magnet # 03 01 - B0602 - 02 1

G Snap-ring, AC Hub # 03 01 - B0602 - 03 1

G Shim, Clutch Hub # 03 01 - B0602 - 04 2

Sub-Subsystem

Part Number

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

System 

ED&T/R&D

(x1000)

BASE TECHNOLOGY GENERAL PART INFORMATION:

Mechanical Air Conditioning Compressor: Electromagnetic Clutch

Item

Subsystem

BASE 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: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, 06=Technology Package, 02=Vehicle Class )

G Bolt, AC Clutch Hub Cover # 03 01 - B0602 - 05 3

G Bolt, Bracket, AC Electrical # 03 01 - B0602 - 06 1

G Bolt, Short, AC Asm to Hoses # 03 01 - B0602 - 72 1

G Bolt, Long, AC Asm. to Bracket # 03 01 - B0602 - 73 1

2 G Center Pump Assembly A $ 4.19 $ 0.39 $ 1.50 $ 6.08 $ 0.04 $ 0.52 $ 0.45 $ 0.18 $ 1.19 $ - $ 7.26 $ -

A G - Center Pump Housing Assembly A (Includes items listed below) # 03 01 - B0602 - 007 1 Full 1 $ 4.19 $ 0.39 $ 1.50 $ 6.08 $ 0.04 $ 0.52 $ 0.45 $ 0.18 $ 1.19 $ - $ 7.26 $ -

G Spacer, Shaft, Large # 03 01 - B0602 - 008 1

G Thrust Bearing, Shaft # 03 01 - B0602 - 009 1

G Spacer, Shaft, Small # 03 01 - B0602 - 010 1

G Bearing, Swash Plate to Piston # 03 01 - B0602 - 011 10

G Spacer, Shaft, Large # 03 01 - B0602 - 012 1

G Thrust Bearing, Shaft # 03 01 - B0602 - 013 1

G Spacer, Shaft, Small # 03 01 - B0602 - 014 1

G Gasket, Pump Housing # 03 01 - B0602 - 015 1

G Bolt, Front to Rear Housing # 03 01 - B0602 - 016 3

G Bolt, Front Cover to Rear # 03 01 - B0602 - 063 5

3 G Rear Pump Housing Assembly B $ 1.73 $ 1.95 $ 2.29 $ 5.97 $ 0.03 $ 0.44 $ 0.39 $ 0.16 $ 1.02 $ - $ 6.99 $ -

A G - Rear Pump Housing Assembly B (Includes items listed below) # 03 01 - B0602 - 017 1 Full 1 $ 1.73 $ 1.95 $ 2.29 $ 5.97 $ 0.03 $ 0.44 $ 0.39 $ 0.16 $ 1.02 $ - $ 6.99 $ -

 G Label, Front Pump Housing # 03 01 - B0602 - 018 1

G Bearing, Needle, AC Pump # 03 01 - B0602 - 019 1

G Dowel, Small, Rear Housing # 03 01 - B0602 - 020 3

G O Ring, Housing, AC Pump # 03 01 - B0602 - 021 1

4 G Shaft and Swash Plate Assembly C $ 1.16 $ 1.18 $ 1.49 $ 3.83 $ 0.08 $ 0.51 $ 0.41 $ 0.11 $ 1.11 $ - $ 4.94 $ -

A G - Shaft and Swash Plate Assembly C (Includes items listed below) # 03 01 - B0602 - 23/24 1 Full 1 $ 1.16 $ 1.18 $ 1.49 $ 3.83 $ 0.08 $ 0.51 $ 0.41 $ 0.11 $ 1.11 $ - $ 4.94 $ -

G Shaft, AC Pump # 03 01 - B0602 - 023 1

G Swash Plate, AC Pump # 03 01 - B0602 - 024 1

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

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

System 

ED&T/R&D

(x1000)

BASE TECHNOLOGY GENERAL PART INFORMATION:

Mechanical Air Conditioning Compressor: Electromagnetic Clutch

Item

Subsystem

BASE 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: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, 06=Technology Package, 02=Vehicle Class )

5 G Piston Assembly D $ 1.46 $ 3.64 $ 5.46 $ 10.56 $ 0.06 $ 0.74 $ 0.67 $ 0.27 $ 1.74 $ - $ 12.31 $ -

A G - Piston Assembly D (Includes items listed below) # 03 01 - B0602 - 025 5 Full 1 $ 1.46 $ 3.64 $ 5.46 $ 10.56 $ 0.06 $ 0.74 $ 0.67 $ 0.27 $ 1.74 $ - $ 12.31 $ -

G Piston, AC Compressor # 03 01 - B0602 - 026 1

G Seal, Piston, AC Compressor # 03 01 - B0602 - 027 1

6 G Front Pump Housing Assembly E $ 2.71 $ 2.07 $ 3.53 $ 8.30 $ 0.04 $ 0.59 $ 0.53 $ 0.22 $ 1.38 $ - $ 9.69 $ -

A G - Front Pump Assembly E (Includes items listed below) # 03 01 - B0602 - 028 1 Full 1 $ 2.71 $ 2.07 $ 3.53 $ 8.30 $ 0.04 $ 0.59 $ 0.53 $ 0.22 $ 1.38 $ - $ 9.69 $ -

 G Label, Front Pump Housing # 03 01 - B0602 - 029 1

G Bearing, Needle, AC Pump # 03 01 - B0602 - 030 1

G Dowel, Large Front Housing # 03 01 - B0602 - 031 2

G O Ring, Housing, AC Pump # 03 01 - B0602 - 032 1

7 G Steel Valve Assembly E1, E2, E3 $ 0.18 $ 0.68 $ 0.92 $ 1.78 $ 0.02 $ 0.23 $ 0.19 $ 0.05 $ 0.48 $ - $ 2.27 $ -

A G - Steel Valve Assembly E1, E2, E3 (Includes items listed below) # 03 01 - B0602 - 33/39 1 Full 1 $ 0.18 $ 0.68 $ 0.92 $ 1.78 $ 0.02 $ 0.23 $ 0.19 $ 0.05 $ 0.48 $ - $ 2.27 $ -

E1 G Steel Valve, AC Pump # 03 01 - B0602 - 033 1

E2 G Valve Plate, Front Cover Assembly # 03 01 - B0602 - 034 1

G Valve Plate, Base # 03 01 - B0602 - 035 1

G Valve Plate, Valve # 03 01 - B0602 - 036 1

G Steel Valve, Top, Stamp # 03 01 - B0602 - 037 1

G Valve Plate, Pin # 03 01 - B0602 - 038 4

E3 G Gasket, Front Cover # 03 01 - B0602 - 039 1

8 G Front Cover Assembly F $ 1.60 $ 1.73 $ 2.18 $ 5.52 $ 0.03 $ 0.40 $ 0.36 $ 0.14 $ 0.93 $ - $ 6.44 $ -

A G - Front Cover Assembly (Includes items listed below) # 03 01 - B0602 - 040 1 Full 1 $ 1.60 $ 1.73 $ 2.18 $ 5.52 $ 0.03 $ 0.40 $ 0.36 $ 0.14 $ 0.93 $ - $ 6.44 $ -

G Seal, Front Cover # 03 01 - B0602 - 041 1

G Snap-ring, Seal Front Cover # 03 01 - B0602 - 042 1

G Dust Seal, Cloth, Front Cover # 03 01 - B0602 - 043 1

9 G Steel Valve Assembly F1, F2, F3 $ 0.20 $ 0.49 $ 0.74 $ 1.42 $ 0.01 $ 0.18 $ 0.15 $ 0.04 $ 0.39 $ - $ 1.81 $ -

A G - Steel Valve Assembly F1, F2, F3 (Includes items listed below) # 03 01 - B0602 - 44/50 1 Full 1 $ 0.20 $ 0.49 $ 0.74 $ 1.42 $ 0.01 $ 0.18 $ 0.15 $ 0.04 $ 0.39 $ - $ 1.81 $ -

F1 G Steel Valve, AC Pump # 03 01 - B0602 - 044 1

F2 G Valve Plate, Rear Cover, Assembly # 03 01 - B0602 - 045 1

G Valve Plate, Base # 03 01 - B0602 - 046 1

G Valve Plate, Valve # 03 01 - B0602 - 047 1

G Steel Valve, Top, Stamp # 03 01 - B0602 - 048 1

G Valve Plate, Pin # 03 01 - B0602 - 049 4

F3 G Gasket, Rear Cover # 03 01 - B0602 - 050 1

10 G Rear Cover Assembly G $ 1.64 $ 1.26 $ 1.53 $ 4.44 $ 0.02 $ 0.31 $ 0.28 $ 0.12 $ 0.73 $ - $ 5.17 $ -

A G - Rear Cover Assembly (Includes items listed below) G - Rear Cover Assembly (Includes items listed below) # 03 01 - B0602 - 051 1 Full 1 $ 1.64 $ $ 1.26 $ 1.53 $ $ 4.44 $ 0.02 $ 0.31 $ 0.28 $ 0.12 $ $ 0.73 $ $ - $ $ 5.17 $ $ -

G O-ring, Plug, Rear Cover # 03 01 - B0602 - 052 1

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

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

System 

ED&T/R&D

(x1000)

BASE TECHNOLOGY GENERAL PART INFORMATION:

Mechanical Air Conditioning Compressor: Electromagnetic Clutch

Item

Subsystem

BASE 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: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, 06=Technology Package, 02=Vehicle Class )

G Plug Asm. , Rear Cover # 03 01 - B0602 - 053 1

11 G Magnet Assembly H $ 4.14 $ 2.23 $ 1.71 $ 8.07 $ 0.07 $ 1.02 $ 0.83 $ 0.24 $ 2.16 $ - $ 10.23 $ -

A G - Magnet Assembly, AC Clutch (Includes items listed below) # 03 01 - B0602 - 054 1 Full 1 $ 4.14 $ 2.23 $ 1.71 $ 8.07 $ 0.07 $ 1.02 $ 0.83 $ 0.24 $ 2.16 $ - $ 10.23 $ -

G Snap-ring, AC Magnet # 03 01 - B0602 - 055 1

G Magnet Asm, Pigtail Connector # 03 01 - B0602 - 056 1

G Magnet Asm, Connector # 03 01 - B0602 - 057 1

G Magnet Asm, Liner # 03 01 - B0602 - 058 1

12 G Clutch Hub Assembly I $ 1.11 $ 1.77 $ 2.05 $ 4.94 $ 0.04 $ 0.65 $ 0.52 $ 0.14 $ 1.35 $ - $ 6.28 $ -

A G - Clutch Hub Assembly (Includes items listed below) # 03 01 - B0602 - 059 1 Full 1 $ 1.11 $ 1.77 $ 2.05 $ 4.94 $ 0.04 $ 0.65 $ 0.52 $ 0.14 $ 1.35 $ - $ 6.28 $ -

G Clutch Hub, W G Clutch Hub, Washer, M5 asher, M5 # 03 01 - B0602 - 060 3

G Clutch Hub, Rivet Pin, M5 # 03 01 - B0602 - 061 3

G Clutch Hub, Rivet Pin, M6 # 03 01 - B0602 - 062 3

I1 G Clutch Hub, Splined Hub, Painted # 03 01 - B0602 - 064 1

I2 G Clutch Hub, Face # 03 01 - B0602 - 065 1

I3 G Clutch Hub, Isolator,Painted, Asm # 03 01 - B0602 - 066 1

I4 G Clutch Hub, Cover, Molded # 03 01 - B0602 - 067 1

13 G Bracket Stamped Assembly J $ 0.01 $ 0.01 $ 0.02 $ 0.04 $ 0.00 $ 0.01 $ 0.00 $ 0.00 $ 0.01 $ - $ 0.05 $ -

A G - Bracket, Stamped AC (Includes items listed below) # 03 01 - B0602 - 068 1 Full 1 $ 0.01 $ 0.01 $ 0.02 $ 0.04 $ 0.00 $ 0.01 $ 0.00 $ 0.00 $ 0.01 $ - $ 0.05 $ -

14 G Clutch Pulley Assembly K $ 3.48 $ 1.49 $ 1.43 $ 6.40 $ 0.13 $ 0.72 $ 0.59 $ 0.17 $ 1.61 $ - $ 8.01 $ -

A G - Clutch Pulley Assembly (Includes items listed below) # 03 01 - B0602 - 069 1 Full 1 $ 3.48 $ 1.49 $ 1.43 $ 6.40 $ 0.13 $ 0.72 $ 0.59 $ 0.17 $ 1.61 $ - $ 8.01 $ -

G Clutch Pully, Friction Material # 03 01 - B0602 - 070 1

G Clutch Pulley, Bearing # 03 01 - B0602 - 071 1

$ 24.10 $ 19.18 $ 25.92 $ 69.20 $ 0.58 $ 6.52 $ 5.56 $ 1.89 $ 14.56 $ - $ 83.75 $ -

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) Yes

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

120301 Refrigeration/Air Conditioning Subsystem - AC Compressor

1 G AC Pump Assembly

A G - AC Pump Assembly (Includes items listed below) # 03 01 - B0602 - 001 1 Full 1

G Snap-ring, AC Magnet # 03 01 - B0602 - 02 1

G Snap-ring, AC Hub # 03 01 - B0602 - 03 1

G Shim, Clutch Hub # 03 01 - B0602 - 04 2

Sub-Subsystem

Part Number

QTY/ Subsystem

Notes

Subassembly

Component

BASE TECHNOLOGY GENERAL PART INFORMATION:

Mechanical Air Conditioning Compressor: Electromagnetic Clutch

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, 06=Technology Package, 02=Vehicle Class )

$ - $ -

$ - $ -

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

G Bolt, AC Clutch Hub Cover # 03 01 - B0602 - 05 3

G Bolt, Bracket, AC Electrical # 03 01 - B0602 - 06 1

G Bolt, Short, AC Asm to Hoses # 03 01 - B0602 - 72 1

G Bolt, Long, AC Asm. to Bracket # 03 01 - B0602 - 73 1

2 G Center Pump Assembly A

A G - Center Pump Housing Assembly A (Includes items listed below) # 03 01 - B0602 - 007 1 Full 1

G Spacer, Shaft, Large # 03 01 - B0602 - 008 1

G Thrust Bearing, Shaft # 03 01 - B0602 - 009 1

G Spacer, Shaft, Small # 03 01 - B0602 - 010 1

G Bearing, Swash Plate to Piston # 03 01 - B0602 - 011 10

G Spacer, Shaft, Large # 03 01 - B0602 - 012 1

G Thrust Bearing, Shaft # 03 01 - B0602 - 013 1

G Spacer, Shaft, Small # 03 01 - B0602 - 014 1

G Gasket, Pump Housing # 03 01 - B0602 - 015 1

G Bolt, Front to Rear Housing # 03 01 - B0602 - 016 3

G Bolt, Front Cover to Rear # 03 01 - B0602 - 063 5

3 G Rear Pump Housing Assembly B

A G - Rear Pump Housing Assembly B (Includes items listed below) # 03 01 - B0602 - 017 1 Full 1

 G Label, Front Pump Housing # 03 01 - B0602 - 018 1

G Bearing, Needle, AC Pump # 03 01 - B0602 - 019 1

G Dowel, Small, Rear Housing # 03 01 - B0602 - 020 3

G O Ring, Housing, AC Pump # 03 01 - B0602 - 021 1

4 G Shaft and Swash Plate Assembly C

A G - Shaft and Swash Plate Assembly C (Includes items listed below) # 03 01 - B0602 - 23/24 1 Full 1

G Shaft, AC Pump # 03 01 - B0602 - 023 1

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

G Swash Plate, AC Pump # 03 01 - B0602 - 024 1

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

BASE TECHNOLOGY GENERAL PART INFORMATION:

Mechanical Air Conditioning Compressor: Electromagnetic Clutch

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, 06=Technology Package, 02=Vehicle Class )

5 G Piston Assembly D

A G - Piston Assembly D (Includes items listed below) # 03 01 - B0602 - 025 5 Full 1

G Piston, AC Compressor # 03 01 - B0602 - 026 1

G Seal, Piston, AC Compressor # 03 01 - B0602 - 027 1

6 G Front Pump Housing Assembly E

A G - Front Pump Assembly E (Includes items listed below) # 03 01 - B0602 - 028 1 Full 1

 G Label, Front Pump Housing # 03 01 - B0602 - 029 1

G Bearing, Needle, AC Pump # 03 01 - B0602 - 030 1

G Dowel, Large Front Housing # 03 01 - B0602 - 031 2

G O Ring, Housing, AC Pump # 03 01 - B0602 - 032 1

Investment

(X1000)

Tooling 

(x1000)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

7 G Steel Valve Assembly E1, E2, E3

A G - Steel Valve Assembly E1, E2, E3 (Includes items listed below) # 03 01 - B0602 - 33/39 1 Full 1

E1 G Steel Valve, AC Pump # 03 01 - B0602 - 033 1

E2 G Valve Plate, Front Cover Assembly # 03 01 - B0602 - 034 1

G Valve Plate, Base # 03 01 - B0602 - 035 1

G Valve Plate, Valve # 03 01 - B0602 - 036 1

G Steel Valve, Top, Stamp # 03 01 - B0602 - 037 1

G Valve Plate, Pin # 03 01 - B0602 - 038 4

E3 G Gasket, Front Cover # 03 01 - B0602 - 039 1

8 G Front Cover Assembly F

A G - Front Cover Assembly (Includes items listed below) # 03 01 - B0602 - 040 1 Full 1

G Seal, Front Cover # 03 01 - B0602 - 041 1

G Snap-ring, Seal Front Cover # 03 01 - B0602 - 042 1

G Dust Seal, Cloth, Front Cover # 03 01 - B0602 - 043 1

9 G Steel Valve Assembly F1, F2, F3

A G - Steel Valve Assembly F1, F2, F3 (Includes items listed below) # 03 01 - B0602 - 44/50 1 Full 1

F1 G Steel Valve, AC Pump # 03 01 - B0602 - 044 1

F2 G Valve Plate, Rear Cover, Assembly # 03 01 - B0602 - 045 1

G Valve Plate, Base # 03 01 - B0602 - 046 1

G Valve Plate, Valve # 03 01 - B0602 - 047 1

G Steel Valve, Top, Stamp # 03 01 - B0602 - 048 1

G Valve Plate, Pin # 03 01 - B0602 - 049 4

F3 G Gasket, Rear Cover # 03 01 - B0602 - 050 1

10 G Rear Cover Assembly G

A G - Rear Cover Assembly (Includes items listed below) # 03 01 - B0602 - 051 1 Full 1

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

A G - Rear Cover Assembly (Includes items listed below) # 03 01 - B0602 - 051 1 Full 1 $ - $ -

G O-ring, Plug, Rear Cover # 03 01 - B0602 - 052 1

$ - $ -

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

BASE TECHNOLOGY GENERAL PART INFORMATION:

Mechanical Air Conditioning Compressor: Electromagnetic Clutch

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, 06=Technology Package, 02=Vehicle Class )

G Plug Asm. , Rear Cover # 03 01 - B0602 - 053 1

11 G Magnet Assembly H

A G - Magnet Assembly, AC Clutch (Includes items listed below) # 03 01 - B0602 - 054 1 Full 1

G Snap-ring, AC Magnet # 03 01 - B0602 - 055 1

G Magnet Asm, Pigtail Connector # 03 01 - B0602 - 056 1

G Magnet Asm, Connector # 03 01 - B0602 - 057 1

G Magnet Asm, Liner # 03 01 - B0602 - 058 1

12 G Clutch Hub Assembly I

A G - Clutch Hub Assembly (Includes items listed below) # 03 01 - B0602 - 059 1 Full 1

G Clutch Hub, Washer, M5 # 03 01 - B0602 - 060 3

Investment

(X1000)

Tooling 

(x1000)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

G Clutch Hub, Washer, M5 # 03 01 - B0602 - 060 3

G Clutch Hub, Rivet Pin, M5 # 03 01 - B0602 - 061 3

G Clutch Hub, Rivet Pin, M6 # 03 01 - B0602 - 062 3

I1 G Clutch Hub, Splined Hub, Painted # 03 01 - B0602 - 064 1

I2 G Clutch Hub, Face # 03 01 - B0602 - 065 1

I3 G Clutch Hub, Isolator,Painted, Asm # 03 01 - B0602 - 066 1

I4 G Clutch Hub, Cover, Molded # 03 01 - B0602 - 067 1

13 G Bracket Stamped Assembly J

A G - Bracket, Stamped AC (Includes items listed below) # 03 01 - B0602 - 068 1 Full 1

14 G Clutch Pulley Assembly K

A G - Clutch Pulley Assembly (Includes items listed below) # 03 01 - B0602 - 069 1 Full 1

G Clutch Pully, Friction Material # 03 01 - B0602 - 070 1

G Clutch Pulley, Bearing # 03 01 - B0602 - 071 1

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) Yes

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

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 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-001 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 G AC Pump Assembly 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 120301-B0602-01 1 Assembly T1 Low Assembly 

Complexity

Not Applicable General Assembly Mech Assembly, MC, 

Base

400 3 2 7 0.000 $0.00 $38.55 $30.00 $420.00 $0.00 $0.29 $1.05 $1.34 0.30% 6.00% 4.00% 1.00% 11.30% $0.15 $1.49 $1.49 $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)

Costs Broken Out In

TOTAL COSTS

47 North America

450,000

1

450,000

T1 Moderate Assembly Complexity

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

9,574

10

TOOLING & INVESTMENT

North America

FOB Ship Point

MARK-UP COSTS Manufacturing Costs 

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

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

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

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

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 G Snap-ring, AC Magnet 120301-B0602-02 1 s $0.00 $0.08 $0.00 $0.08 $0.08

2 G Snap-ring, AC Hub 120301-B0602-03 1 s $0.00 $0.08 $0.00 $0.08 $0.08

3 G Shim, Clutch Hub 120301-B0602-04 2 s $0.00 $0.01 $0.00 $0.02 $0.02

4 G Bolt, AC Clutch Hub Cover 120301-B0602-05 3 s $0.00 $0.01 $0.00 $0.03 $0.03

5 G Bolt, Bracket, AC Electrical 120301-B0602-06 1 s $0.00 $0.01 $0.00 $0.01 $0.01

6 G Bolt, Short, AC Asm to Hoses 120301-B0602-72 1 s $0.00 $0.06 $0.00 $0.06 $0.06

7 G Bolt, Long, AC Asm. to Bracket 120301-B0602-73 1 s $0.00 $0.22 $0.00 $0.22 $0.22

8 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

Material

$0.50

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

Mark-up $1.99

T1 or OEM Total Manufacturing Cost: $0.50 $0.29 $1.05 $1.84 $0.00 $0.08 $0.05 $0.01 $0.15 $1.99

"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.

3

1

Notes: 

T1 or OEM Mark-Up Rates: a) Items 1,2, & 3 must a----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.13 $0.12 $0.05 $0.31

Base Cost Impact to Vehicle: $0.50 $0.29 $1.05 $1.84 $0.01 $0.21 $0.17 $0.06 $0.46 $2.30 $0 $0

Packaging Cost: $0.01

Net Cost Impact to Vehicle: $2.30

a) Items 1,2, & 3 must a

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: 2 of 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-001 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

TOTAL COSTS

47 North America

450,000

1

450,000

T1 Moderate Assembly Complexity

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

9,574

10

TOOLING & INVESTMENT

North America

FOB Ship Point

MARK-UP COSTS Manufacturing Costs 

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

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

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: $0.006 $11,600 0.00% 2,250,000 60 5.00% $200 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: $0.006

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: 3 of 6 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)

G AC Pump Assembly

120301-B0602-01

Purchase Part - High Impact Item (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

$0.29 $1.05 $1.34 $0.00 $0.08 $0.05 $0.01 $0.15 Automated Linear Transfer Line, combination of manual and automated 

assembly, 3 manual stations, 4 automated stations. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 137 35 1 18 7.0 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

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

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

G Snap-ring, AC Magnet 120301-B0602-02

G Snap-ring, AC Hub 120301-B0602-03

G Shim, Clutch Hub 120301-B0602-04

G Bolt, AC Clutch Hub Cover 120301-B0602-05

G Bolt, Bracket, AC Electrical 120301-B0602-06

G Bolt, Short, AC Asm to Hoses 120301-B0602-72

G Bolt, Long, AC Asm. to Bracket 120301-B0602-73

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

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

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

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

$0.08

$0.08

$0.02

$0.03

$0.01

$0.06

$0.22

$0.00

$0.00

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

Total

$0.29 $1.05 $1.84 $0.00 $0.08 $0.05 $0.01 $0.15

$1.99

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: 4 of 6 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 Project Process Requirement

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity

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 6 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)

G AC Pump Assembly

120301-B0602-01

Purchase Part - High Impact Item (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! -

400 9.00 3.00

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

G Snap-ring, AC Magnet 120301-B0602-02

G Snap-ring, AC Hub 120301-B0602-03

G Shim, Clutch Hub 120301-B0602-04

G Bolt, AC Clutch Hub Cover 120301-B0602-05

G Bolt, Bracket, AC Electrical 120301-B0602-06

G Bolt, Short, AC Asm to Hoses 120301-B0602-72

G Bolt, Long, AC Asm. to Bracket 120301-B0602-73

#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: 6 of 6 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: 1 of 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-007 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

G Center Pump Assembly

0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 120301-B0602-07 1 Assembly T1 Low Assembly 

Complexity

Not Applicable General Assembly Mech Assembly, MC, 

Base

400 4 2 10 0.000 $0.00 $38.55 $30.00 $600.00 $0.00 $0.39 $1.50 $1.89 0.30% 6.00% 4.00% 1.00% 11.30% $0.21 $2.10 $2.10 $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

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

Purchase Part - High Impact Item (Full Cost Mapping)

Costs Broken Out In

TOTAL COSTS

47 North America

450,000

1

450,000

T1 Moderate Assembly Complexity

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

9,574

10

TOOLING & INVESTMENT

North America

FOB Ship Point

MARK-UP COSTS Manufacturing Costs 

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

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

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

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 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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

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 G Spacer, Shaft, Large 120301-B0602-08 1 S $0.00 $0.12 $0.00 $0.12 $0.12

2 G Thrust Bearing, Shaft 120301-B0602-09 1 S $0.00 $0.17 $0.00 $0.17 $0.17

3 G Spacer, Shaft, Small 120301-B0602-10 1 S $0.00 $0.11 $0.00 $0.11 $0.11

4 G Bearing, Swash Plate to Piston 120301-B0602-11 10 S $0.00 $0.20 $0.00 $2.00 $2.00

5 G Spacer, Shaft, Large 120301-B0602-12 1 S $0.00 $0.12 $0.00 $0.12 $0.12

6 G Thrust Bearing, Shaft 120301-B0602-13 1 S $0.00 $0.17 $0.00 $0.17 $0.17

7 G Spacer, Shaft, Small 120301-B0602-14 1 S $0.00 $0.11 $0.00 $0.11 $0.11

8 G Gasket, Pump Housing 120301-B0602-15 1 S $0.00 $0.07 $0.00 $0.07 $0.07

9 G Bolt, Front to Rear Housing 120301-B0602-16 3 S $0.00 $0.04 $0.00 $0.12 $0.12

10 G Bolt, Front Cover to Rear 120301-B0602-63 5 S $0.00 $0.24 $0.00 $1.20 $1.20

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

Material

$4.19

"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.

$4.19

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

Mark-up $6.29

T1 or OEM Total Manufacturing Cost: $4.19 $0.39 $1.50 $6.08 $0.01 $0.11 $0.08 $0.02 $0.21 $6.29

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 $0.41 $0.38 $0.16 $0.97

Base Cost Impact to Vehicle: $4.19 $0.39 $1.50 $6.08 $0.04 $0.52 $0.45 $0.18 $1.19 $7.26 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $7.26

3

1

Notes: 

a) Items 1,2, & 3 must a

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 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-007 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

TOTAL COSTS

47 North America

450,000

1

450,000

T1 Moderate Assembly Complexity

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

9,574

10

TOOLING & INVESTMENT

North America

FOB Ship Point

MARK-UP COSTS Manufacturing Costs 

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

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

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% 58 1000 6 57447

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

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

Packaging Cost Total: $0.000

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: 3 of 6 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)

G Center Pump Assembly

120301-B0602-07

Purchase Part - High Impact Item (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

$0.39 $1.50 $1.89 $0.01 $0.11 $0.08 $0.02 $0.21 Automated Linear Transfer Line, combination of manual and automated 

assembly, 4 manual stations, 6 automated stations. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 211 51 1 18 10.0 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

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

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

G Spacer, Shaft, Large 120301-B0602-08

G Thrust Bearing, Shaft 120301-B0602-09

G Spacer, Shaft, Small 120301-B0602-10

G Bearing, Swash Plate to Piston 120301-B0602-11

G Spacer, Shaft, Large 120301-B0602-12

G Thrust Bearing, Shaft 120301-B0602-13

G Spacer, Shaft, Small 120301-B0602-14

G Gasket, Pump Housing 120301-B0602-15

G Bolt, Front to Rear Housing 120301-B0602-16

G Bolt, Front Cover to Rear 120301-B0602-63

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

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

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

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

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

$0.12

$0.17

$0.11

$2.00

$0.12

$0.17

$0.11

$0.07

$0.12

$1.20

$0.00

$0.00

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

Total

$0.39 $1.50 $6.08 $0.01 $0.11 $0.08 $0.02 $0.21

$6.29

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: 4 of 6 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 Project Process Requirement

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity

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 6 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)

G Center Pump Assembly

120301-B0602-07

Purchase Part - High Impact Item (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! -

400 9.00 4.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

G Spacer, Shaft, Large 120301-B0602-08

G Thrust Bearing, Shaft 120301-B0602-09

G Spacer, Shaft, Small 120301-B0602-10

G Bearing, Swash Plate to Piston 120301-B0602-11

G Spacer, Shaft, Large 120301-B0602-12

G Thrust Bearing, Shaft 120301-B0602-13

G Spacer, Shaft, Small 120301-B0602-14

G Gasket, Pump Housing 120301-B0602-15

G Bolt, Front to Rear Housing 120301-B0602-16

G Bolt, Front Cover to Rear 120301-B0602-63

#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: 6 of 6 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: 1 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Locatio

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

Study Case#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classificatio

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Metho

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-17 Weekly Component Volume: Packaging Specificatio

Component Quote Level: Estimated Product Life: Production Yea

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

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

1

G Rear Pump Housing, Asm.

120301-B0602-17 1

2 Press/subassembly 120301-B0602-17-01 1 Press T1 Low Assembly 

Complexity Not Applicable General Assembly Mech Assembly, LC, Base

141 2 1 2 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.55 $0.21 $0.76 0.30% 6.00% 4.00% 1.00% 11.30%

3

Wash (1 Wash Cycles thru machining)

120301-B0602-17-02 1 1 Wash Cycles thru machining Not Applicable Not Applicable CNC Operator Washing 

Equipment, LC

360 0.25 1 1 0.000 $0.00 $36.98 $10.75 $10.75 $0.00 $0.03 $0.03 $0.06 0.00% 0.00% 0.00% 0.00% 0.00%

450,000

9,574

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

47

450,000

1

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS

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

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

4

Machine

120301-B0602-17-03 1 Machine Not Applicable Not Applicable CNC Operator CNC Machining, 

LC

107 3 6 1 0.000 $0.00 $36.98 $30.38 $182.28 $0.00 $1.03 $1.70 $2.73 0.00% 0.00% 0.00% 0.00% 0.00%

5 Heat Treat 120301-B0602-17-04 1 Heat Treat Not Applicable Not Applicable Heat Treat Operator T5-Al380, SMS 289 1.5 1 1 0.904 $0.01 $47.72 $10.17 $10.17 $0.01 $0.25 $0.04 $0.29 0.00% 0.00% 0.00% 0.00% 0.00%

10 G Rear Pump Housing-Casting 120301-B0602-17-05 1 G Rear Pump Housing-Cast Not Applicable Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC 410 1 1 1.1 0.904 $1.10 $41.48 $116.73 $128.40 $0.99 $0.10 $0.31 $1.41 0.00% 0.00% 0.00% 0.00% 0.00%

11 0 #DIV/0! 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

1 0 #DIV/0! 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #REF! #REF! #REF! #REF! #REF!

30 0 #DIV/0! 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

#### 0 #DIV/0! 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

#### 0 #DIV/0! 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A

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

Supplier 

Account 

Cost

1 G Bearing, Needle, AC Pump 120301-B0602-19 1 s $0.00

2 G Dowel, Small, Rear Housing 120301-B0602-20 3 s $0.00

3 G Oing, Housing, AC Pump 120301-B0602-21 1 s $0.00

4 G Label, Rear Pump Housing 120301-B0602-18 1 s $0.00

5 0 $0.00

30 0 $0.00

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

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

Sub-Assembly.

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

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

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

Mark-up

T1 or OEM Total Manufacturing Cost: $1.73 $1.95 $2.29 $5.97 $0.00 $0.05 $0.03 $0.01 $0.09

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 $0.39 $0.36 $0.15 $0.94

Base Cost Impact to Vehicle: $1.73 $1.95 $2.29 $5.97 $0.03 $0.44 $0.39 $0.16 $1.02

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

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 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Locatio

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

Study Case#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classificatio

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Metho

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-17 Weekly Component Volume: Packaging Specificatio

Component Quote Level: Estimated Product Life: Production Yea

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

450,000

9,574

10

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

47

450,000

1

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS

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

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

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% 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per Divider Pads Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

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

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

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: 3 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

G Rear Pump Housing, Asm.

120301-B0602-17

Press/subassembly 120301-B0602-17-01

Wash (1 Wash Cycles thru machining)

120301-B0602-17-02

GENERAL COMPONENT INFORMATION

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

Supplier Plant Location:

OEM/T1 Classification:

Shipping Method:

Packaging Specification: Returnable Dunnage 209

Production Year: 2008/2009

Total Mark-up Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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."

$0.09 $0.84 $0.84 $0.00 $0.55 $0.21 $0.76 $0.00 $0.05 $0.03 $0.01 $0.09

T1 Low Assembly Complexity, 2 Semi 

automated workcells, operator 

load/unload. 

5 2 10 100 47 4700 96 37.60 85% 113 31.96 81

$0.00 $0.06 $0.06 $0.00 $0.03 $0.03 $0.06 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 Wash Rinse & Dry 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13

T1 Moderate Assembly Complexity

Projected Operating Pattern Minimum Calculated Cycles Time 

North America

North America

FOB Ship Point

MARK-UP COSTS

MANUFACTURING ASSUMPTIONS

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

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

TOTAL COSTS TOOLING & INVESTMENT

Machine

120301-B0602-17-03

Heat Treat 120301-B0602-17-04

G Rear Pump Housing-Casting 120301-B0602-17-05

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

G Bearing, Needle, AC Pump 120301-B0602-19

G Dowel, Small, Rear Housing 120301-B0602-20

G Oing, Housing, AC Pump 120301-B0602-21

 G Label, Rear Pump Housing 120301-B0602-18

$0.00 $2.73 $2.73 $0.00 $1.03 $1.70 $2.73 $0.00 $0.00 $0.00 $0.00 $0.00 EC-300-AL Horizontal CNC , Pallet 

Size 300 mm2 550 lb capacity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 209

$0.00 $0.29 $0.29 $0.01 $0.25 $0.04 $0.29 $0.00 $0.00 $0.00 $0.00 $0.00 T5 Heat Treat 5 2 10 100 47 4700 96 37.60 85% 113 31.96 -

$0.00 $1.41 $1.41 $0.99 $0.10 $0.31 $1.41 $0.00 $0.00 $0.00 $0.00 $0.00 1.1 Multiplier used for trimming 5 2 10 100 47 4700 96 37.60 85% 113 31.96 8.77

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

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

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

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

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

Purchase Price/ Unit Purchase 

Price Net, PIA

Purchase 

Price Net, 

End Item

$0.55 $0.00 $0.55 $0.55 $0.55

$0.02 $0.00 $0.05 $0.02 $0.02

$0.06 $0.00 $0.06 $0.06 $0.06

$0.10 $0.00 $0.10 $0.10 $0.10

$0.00 $0.00 $0.00 $0.00 $0.00

$0.00 $0.00 $0.00 $0.00 $0.00

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

Total

$1.73 $1.95 $2.29 $5.97 $0.00 $0.05 $0.03 $0.01 $0.09

1 $6.09 $6.06

2

$6.06

$6.99 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $6.99

3

1

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: 4 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Supplier Plant Location:

OEM/T1 Classification:

Shipping Method:

Packaging Specification: Returnable Dunnage 209

Production Year: 2008/2009

Total Mark-up Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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."

T1 Moderate Assembly Complexity

Projected Operating Pattern Minimum Calculated Cycles Time 

North America

North America

FOB Ship Point

MARK-UP COSTS

MANUFACTURING ASSUMPTIONS

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

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

TOTAL COSTS TOOLING & INVESTMENT

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 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

G Rear Pump Housing, Asm.

120301-B0602-17

Press/subassembly 120301-B0602-17-01

Wash (1 Wash Cycles thru machining)

120301-B0602-17-02

GENERAL COMPONENT INFORMATION

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

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

 24 1 25.5 2.0 1.0 141 25.50 2.00

 5 1 10 1.0 1.0 360 10.00 0.25

Project Process Requirement

Machine

120301-B0602-17-03

Heat Treat 120301-B0602-17-04

G Rear Pump Housing-Casting 120301-B0602-17-05

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

G Bearing, Needle, AC Pump 120301-B0602-19

G Dowel, Small, Rear Housing 120301-B0602-20

G Oing, Housing, AC Pump 120301-B0602-21

 G Label, Rear Pump Housing 120301-B0602-18

 94 1 201 1.0 6.0 107 33.57 3.00

 - 2,170 27,000 1.0 1.0 289 12.44 1.50

 2 4 35 1.1 1.0 410 8.77 1.00

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

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

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

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

 - - - 1.0 1.0 #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: 6 of 6 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

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.

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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: 1 of 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-23/24 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

G Shaft and Swash Plate Asm.

##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 120301-B0602-22-01 1 Assembly T1 Low Assembly Complexity Not Applicable General Assembly Mech Assembly, LC, Base 400 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.10 $0.04 $0.13 0.30% 6.00% 4.00% 1.00% 11.30% $0.02 $0.15 $0.15 $0.00

Costs Broken Out In

TOTAL COSTS

47 North America

450,000

1

450,000

T1 Moderate Assembly Complexity

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

9,574

10

TOOLING & INVESTMENT

North America

FOB Ship Point

MARK-UP COSTS Manufacturing Costs 

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

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

6 Swash Plate 120301-B0602-24-01 1

1 Wash Cycles thru 

machining T2/T3 CNC Turning, SSLC Not Applicable CNC Operator Washing Equipment, MC 360 0.5 1 1 0.000 $0.00 $36.98 $49.38 $49.38 $0.00 $0.05 $0.14 $0.19 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.21 $0.21 $0.00

7 120301-B0602-24-03 1 Heat Treat T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator T5-Al380, SMS 579 1.5 1 1 0.492 $0.01 $47.72 $10.17 $10.17 $0.01 $0.12 $0.02 $0.15 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.16 $0.16 $0.01

8 120301-B0602-24-04 1 Cast T2/T3 Diecast, SSLC Aluminum-B390, Cast Mold/Cast/Sinter Operator Diecast, LMC 402 1 1 1.1 0.492 $1.20 $41.48 $116.73 $128.40 $0.59 $0.10 $0.32 $1.01 5.00% 6.00% 4.00% 0.00% 15.00% $0.15 $1.16 $1.16 $0.59

9 Shaft 120301-B0602-23-01 1

1 Wash Cycles thru 

machining T2/T3 CNC Turning, SSLC Not Applicable CNC Operator Washing Equipment, LC 360 0.5 1 1 0.000 $0.00 $36.98 $10.75 $10.75 $0.00 $0.05 $0.03 $0.08 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.09 $0.09 $0.00

10 120301-B0602-23-02 1 Broach/Machine T2/T3 CNC Turning, SSLC Not Applicable CNC Operator CNC Turning, SS, BF, DA 343 1 1 1 0.000 $0.00 $36.98 $20.48 $20.48 $0.00 $0.11 $0.06 $0.17 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $0.00

11 120301-B0602-23-03 1 Bar Feed/Broach T2/T3 CNC Turning, SSLC HC-Steel-1040S, Bar CNC Operator DS-CNC Turning, SS, BF, DA 114 2 4 1 0.700 $0.80 $36.98 $25.52 $102.08 $0.56 $0.65 $0.89 $2.10 0.30% 6.00% 4.00% 0.00% 10.30% $0.22 $2.32 $2.32 $0.56

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

32 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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

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

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

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

Material

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

$1.16

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

Mark-up $4.28

T1 or OEM Total Manufacturing Cost: $1.16 $1.18 $1.49 $3.83 $0.06 $0.23 $0.15 $0.00 $0.44 $4.28

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 ----- ----- ----- $0.02 $0.28 $0.26 $0.11 $0.66

Base Cost Impact to Vehicle: $1.16 $1.18 $1.49 $3.83 $0.08 $0.51 $0.41 $0.11 $1.11 $4.94 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $4.94

3

1

Notes: 

a) Items 1,2, & 3 must a

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 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-23/24 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

TOTAL COSTS

47 North America

450,000

1

450,000

T1 Moderate Assembly Complexity

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

9,574

10

TOOLING & INVESTMENT

North America

FOB Ship Point

MARK-UP COSTS Manufacturing Costs 

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

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

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% 58 1000 6 57447

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

Packaging Cost Total: $0.000

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

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

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

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

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

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

File: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 6 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)

G Shaft and Swash Plate Asm.

120301-B0602-22-01

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

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

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

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

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

$0.10 $0.04 $0.13 $0.00 $0.01 $0.01 $0.00 $0.02 T1 Low Assembly Complexity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 9 5 1 9 1.0 1.0

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

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity

Swash Plate 120301-B0602-24-01

120301-B0602-24-03

120301-B0602-24-04

Shaft 120301-B0602-23-01

120301-B0602-23-02

120301-B0602-23-03

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

$0.05 $0.14 $0.19 $0.00 $0.01 $0.01 $0.00 $0.02 Washer Duo 400 Wash Rinse & Dry 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 5 1 10 1.0 1.0

$0.12 $0.02 $0.15 $0.00 $0.01 $0.01 $0.00 $0.02 T5 Heat treat 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - - 4,340 27,000 1.0 1.0

$0.10 $0.32 $1.01 $0.05 $0.06 $0.04 $0.00 $0.15 Die Cast 500-100 ton1.1 Multiplier for trim operations 5 2 10 100 47 4700 96 37.60 85% 113 31.96 9 2 8 72 1.1 1.0

$0.05 $0.03 $0.08 $0.00 $0.00 $0.00 $0.00 $0.01 Washer Duo 400 Wash Rinse & Dry 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 5 1 10 1.0 1.0

$0.11 $0.06 $0.17 $0.00 $0.01 $0.01 $0.00 $0.02 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 2 1 11 1.0 1.0

$0.65 $0.89 $2.10 $0.01 $0.13 $0.08 $0.00 $0.22 CNC TL-15 2 Axis, Lathe - Auto Load Includes Bar Feeder 5 2 10 100 47 4700 96 37.60 85% 113 31.96 126 66 1 126 1.0 4.0

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

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

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

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

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

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

$0.00

$0.00

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

Total

$1.18 $1.49 $3.83 $0.06 $0.23 $0.15 $0.00 $0.44

$4.28

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: 4 of 6 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 Project Process Requirement

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity

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 6 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)

G Shaft and Swash Plate Asm.

120301-B0602-22-01

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

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

400 9.00 1.00

Swash Plate 120301-B0602-24-01

120301-B0602-24-03

120301-B0602-24-04

Shaft 120301-B0602-23-01

120301-B0602-23-02

120301-B0602-23-03

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

360 10.00 0.50

579 6.22 1.50

402 8.95 1.00

360 10.00 0.50

343 10.50 1.00

114 31.50 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! -

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 6 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: 1 of 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-25 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

G Piston Asm. AC Compressor

120301-B0602-25

2 Assembly 120301-B0602-25-01 5

Assembly

T1 Low Assembly Complexity Not Applicable

General Assembly

None 720 3 3 1 0.000 $0.00 $38.55 $0.00 $0.00 $0.00 $0.16 $0.00 $0.16 0.30% 6.00% 4.00% 1.00% 11.30% $0.02 $0.18 $0.89 $0.00

3 Anodize 120301-B0602-25-02 5 Anodize T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Plating/Coating Operator Anodize, SMS, MHC 720 4 2 1 0.000 $0.00 $40.84 $150.00 $300.00 $0.00 $0.23 $0.42 $0.64 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.64 $3.22 $0.00

4 Machine 120301-B0602-26-02 5 Machine Not Applicable Not Applicable CNC Operator CNC Turning, SS, BF, DA 559 4 16 1 0.000 $0.00 $36.98 $20.48 $327.68 $0.00 $0.26 $0.59 $0.85 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.85 $4.25 $0.00

T5-Al380, SMS

Costs Broken Out In

TOTAL COSTS

47 North America

450,000

1

450,000

T1 Moderate Assembly Complexity

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

9,574

10

TOOLING & INVESTMENT

North America

FOB Ship Point

MARK-UP COSTS Manufacturing Costs 

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

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

5 Heat Treat 120301-B0602-26-03 5 Heat Treat Not Applicable Not Applicable Heat Treat Operator T5-Al380, SMS 2333 1.5 1 1 0.196 $0.01 $47.72 $10.17 $10.17 $0.00 $0.03 $0.00 $0.04 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.04 $0.19 $0.01

6 Cast 120301-B0602-26-04 5 Cast Not Applicable Aluminum-B390, Cast Mold/Cast/Sinter Operator Diecast, SS 907 1 1 1.1 0.196 $1.20 $41.48 $70.80 $77.88 $0.24 $0.05 $0.09 $0.37 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.37 $1.83 $1.18

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #REF! #REF! #REF! #REF! #REF! #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

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

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

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

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 0 $0.00 $0.00 $0.00 $0.00 $0.00

2 G Seal, Piston, AC Compressor 120301-B0602-27 10 s $0.00 $0.03 $0.00 $0.27 $0.27

3 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

$1.46

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

Mark-up $10.66

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

1

T1 or OEM Total Manufacturing Cost: $1.46 $3.64 $5.46 $10.56 $0.00 $0.05 $0.03 $0.01 $0.09 $10.66

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 ----- ----- ----- $0.05 $0.69 $0.64 $0.27 $1.65

Base Cost Impact to Vehicle: $1.46 $3.64 $5.46 $10.56 $0.06 $0.74 $0.67 $0.27 $1.74 $12.31 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $12.31

3

Notes: 

a) Items 1,2, & 3 must a

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: 2 of 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-25 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

TOTAL COSTS

47 North America

450,000

1

450,000

T1 Moderate Assembly Complexity

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

9,574

10

TOOLING & INVESTMENT

North America

FOB Ship Point

MARK-UP COSTS Manufacturing Costs 

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

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

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% 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: 3 of 6 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)

G Piston Asm. AC Compressor

120301-B0602-25

Assembly 120301-B0602-25-01

Anodize 120301-B0602-25-02

Machine 120301-B0602-26-02

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

$0.80 $0.00 $0.80 $0.00 $0.05 $0.03 $0.01 $0.09 T1 Low Assembly Complexity 5 2 10 100 47 4700 479 7.52 85% 563 6.39 23 9 1 15 1.0 3.0

$1.13 $2.08 $3.22 $0.00 $0.00 $0.00 $0.00 $0.00 Automated Load-Unload 8 Station, Linear\ Anodizing System 5 2 10 100 47 4700 479 7.52 85% 563 6.39 - 8 1 10 1.0 2.0

$1.32 $2.93 $4.25 $0.00 $0.00 $0.00 $0.00 $0.00 CNC Turning 4 Axis SL-10, Odd Form 5 2 10 100 47 4700 479 7.52 85% 563 6.39 103 40 1 103 1.0 16.0

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

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity

Heat Treat 120301-B0602-26-03

Cast 120301-B0602-26-04

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

G Seal, Piston, AC Compressor 120301-B0602-27

$0.15 $0.02 $0.19 $0.00 $0.00 $0.00 $0.00 $0.00 T5 Heat Treat 5 2 10 100 47 4700 479 7.52 85% 563 6.39 - - 17,500 27,000 1.0 1.0

$0.23 $0.43 $1.83 $0.00 $0.00 $0.00 $0.00 $0.00 Die Cast 0 -500 ton 1.1 Multiplier used for trim operations 5 2 10 100 47 4700 479 7.52 85% 563 6.39 4 2 10 40 1.1 1.0

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

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

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

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

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

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

$0.00

$0.27

$0.00

$0.00

$0.00

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

Total

$3.64 $5.46 $10.56 $0.00 $0.05 $0.03 $0.01 $0.09

$10.66

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: 4 of 6 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 Project Process Requirement

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity

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 6 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)

G Piston Asm. AC Compressor

120301-B0602-25

Assembly 120301-B0602-25-01

Anodize 120301-B0602-25-02

Machine 120301-B0602-26-02

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

720 5.00 3.00

720 5.00 4.00

559 6.44 4.00

Heat Treat 120301-B0602-26-03

Cast 120301-B0602-26-04

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

G Seal, Piston, AC Compressor 120301-B0602-27

2333 1.54 1.50

907 3.97 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! -

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 6 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: 1 of 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-28 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

G Front Pump Housing, Asm

120301-B0602-28 0

2 Press/subassembly 120301-B0602-28-01 1 Press T1 Low Assembly Complexity Not Applicable

General Assembly Mech Assembly, LC, Base

180 2 1 2 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.43 $0.17 $0.59 0.30% 6.00% 4.00% 1.00% 11.30% $0.07 $0.66 $0.66 $0.00

3 1 Wash Cycles thru machining 120301-B0602-28-02 1 1 Wash Cycles thru machining Not Applicable Not Applicable CNC Operator Washing Equipment, LC 257 0.25 1 1 0.000 $0.00 $36.98 $10.75 $10.75 $0.00 $0.04 $0.04 $0.08 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.08 $0.08 $0.00

4 Machine 120301-B0602-28-03 1 Machine Not Applicable Not Applicable CNC Operator CNC Machining, LC 127 3 10 1 0.000 $0.00 $36.98 $30.38 $303.80 $0.00 $0.87 $2.39 $3.26 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $3.26 $3.26 $0.00

5 Heat Treat 120301-B0602-28-04 1 Heat Treat Not Applicable Not Applicable Heat Treat Operator T5-Al380, SMS 119 1.5 1 1 1.864 $0.01 $47.72 $10.17 $10.17 $0.02 $0.60 $0.09 $0.71 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.71 $0.71 $0.02

Costs Broken Out In

TOTAL COSTS

47 North America

450,000

1

450,000

T1 Moderate Assembly Complexity

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

9,574

10

TOOLING & INVESTMENT

North America

FOB Ship Point

MARK-UP COSTS Manufacturing Costs 

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

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

6

G Front Pump Housing, Cast 120301-B0602-28-05 1G Front Pump Housing, Cast

Not Applicable

Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, MHC 321 1 1 1.1 1.864 $1.10 $41.48 $247.89 $272.68 $2.05 $0.13 $0.85 $3.03 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $3.03 $3.03 $2.05

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

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

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

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

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 G Bearing, Needle, AC Pump 120301-B0602-30 1 s $0.00 $0.55 $0.00 $0.55 $0.55

2 G Dowel, Large Front Housing 120301-B0602-31 2 s $0.00 $0.02 $0.00 $0.03 $0.03

3 G Oing, Housing, AC Pump 120301-B0602-32 1 s $0.00 $0.06 $0.00 $0.06 $0.06

4 G Label, Rear Pump Housing 120301-B0602-29 1 s $0.00 $0.00 $0.00 $0.00 $0.00

5 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

Material

$2.71

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

Mark-up $8.37

"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 

Material Labor Burden TMC Scrap SG&A Profit ED&T 1

Mark-up $8.37

T1 or OEM Total Manufacturing Cost: $2.71 $2.07 $3.53 $8.40 $0.00 $0.04 $0.02 $0.01 $0.07 $8.47

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 ----- ----- ----- $0.04 $0.55 $0.51 $0.21 $1.31

Base Cost Impact to Vehicle: $2.71 $2.07 $3.53 $8.30 $0.04 $0.59 $0.53 $0.22 $1.38 $9.69 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $9.69

3

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

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 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-28 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

TOTAL COSTS

47 North America

450,000

1

450,000

T1 Moderate Assembly Complexity

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

9,574

10

TOOLING & INVESTMENT

North America

FOB Ship Point

MARK-UP COSTS Manufacturing Costs 

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

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

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% 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

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

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: 3 of 6 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)

G Front Pump Housing, Asm

120301-B0602-28

Press/subassembly 120301-B0602-28-01

1 Wash Cycles thru machining 120301-B0602-28-02

Machine 120301-B0602-28-03

Heat Treat 120301-B0602-28-04

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

$0.43 $0.17 $0.59 $0.00 $0.04 $0.02 $0.01 $0.07 T1 Low Assembly Complexity, Two Workcells, manual load, semi automated 

press

5 2 10 100 47 4700 96 37.60 85% 113 31.96 70 20 1 20 2.0 1.0

$0.04 $0.04 $0.08 $0.00 $0.00 $0.00 $0.00 $0.00 Washer Duo 400 Wash Rinse & Dry 5 2 10 100 47 4700 96 37.60 85% 113 31.96 14 5 1 14 1.0 1.0

$0.87 $2.39 $3.26 $0.00 $0.00 $0.00 $0.00 $0.00 EC-300-AL Horizontal CNC , Pallet Size 300 mm2 550 lb capacity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 283 128 1 283 1.0 10.0

$0.60 $0.09 $0.71 $0.00 $0.00 $0.00 $0.00 $0.00 T5 Heat Treat 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - - 896 27,000 1.0 1.0

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

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity

G Front Pump Housing, Cast 120301-B0602-28-05

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

G Bearing, Needle, AC Pump 120301-B0602-30

G Dowel, Large Front Housing 120301-B0602-31

G Oing, Housing, AC Pump 120301-B0602-32

 G Label, Rear Pump Housing 120301-B0602-29

$0.13 $0.85 $3.03 $0.00 $0.00 $0.00 $0.00 $0.00 Aluminum Diecasting, Medium 1000-1800 Ton 1.1 Multiplier used for Trim 

operation 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 2 4 45 1.1 1.0

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

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

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

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

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

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

$0.55

$0.03

$0.06

$0.10

$0.00

$0.00

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

Total

$2.07 $3.53 $8.40 $0.00 $0.04 $0.02 $0.01 $0.07

$8.47

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: 4 of 6 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 Project Process Requirement

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity

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 6 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)

G Front Pump Housing, Asm

120301-B0602-28

Press/subassembly 120301-B0602-28-01

1 Wash Cycles thru machining 120301-B0602-28-02

Machine 120301-B0602-28-03

Heat Treat 120301-B0602-28-04

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

180 20.00 2.00

257 14.00 0.25

127 28.30 3.00

119 30.13 1.50

G Front Pump Housing, Cast 120301-B0602-28-05

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

G Bearing, Needle, AC Pump 120301-B0602-30

G Dowel, Large Front Housing 120301-B0602-31

G Oing, Housing, AC Pump 120301-B0602-32

 G Label, Rear Pump Housing 120301-B0602-29

321 11.23 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! -

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 6 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: 1 of 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-33/38 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

 G Steel Valve, AC Pump Front Cover 

120301-B0602-33 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 120301-B0602-33-01 1 Wash T2/T3 CNC Turning, SSLC Not Applicable CNC Operator Washing Equipment, MC 360 0.25 1 1 0.000 $0.00 $36.98 $49.38 $49.38 $0.00 $0.03 $0.14 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $0.00

3 120301-B0602-33-03 1 G Steel Valve,Stamp T2/T3 Stamp/Form, SSLC HC-Steel-1000S, Coil

Cut/Punch/Forming OperatorOEMStamp/Form, SS

2118 0.25 1 1 0.067 $0.65 $135.07 $42.91 $42.91 $0.04 $0.02 $0.02 $0.08 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.09 $0.09 $0.04

4 G Gasket, Front Cover 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 120301-B0602-39 1

G Gasket, Stamp

T2/T3 Stamp/Form, SSLC HC-Steel-1000S, Coil

Cut/Punch/Forming OperatorOEMStamp/Form, Terminals

5143 0.25 1 1 0.075 $0.65 $135.07 $15.50 $15.50 $0.05 $0.01 $0.00 $0.06 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.06 $0.06 $0.05

Costs Broken Out In

TOTAL COSTS

47 North America

450,000

1

450,000

T1 Moderate Assembly Complexity

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

9,574

10

TOOLING & INVESTMENT

North America

FOB Ship Point

MARK-UP COSTS Manufacturing Costs 

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

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

5 120301-B0602-39 1 T2/T3 Stamp/Form, SSLC HC-Steel-1000S, Coil OEM 5143 0.25 1 1 0.075 $0.65 $135.07 $15.50 $15.50 $0.05 $0.01 $0.00 $0.06 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.06 $0.06 $0.05

6

G Valve Plate, Front Cover

120301-B0602-34 1 Assembly T2/T3 Mech. Assembly, SSLC Not Applicable

General Assembly Mech Assembly, LC, Base

126 1.5 1.5 1 0.000 $0.00 $38.55 $15.00 $22.50 $0.00 $0.46 $0.18 $0.64 0.30% 6.00% 4.00% 0.00% 10.30% $0.07 $0.71 $0.71 $0.00

7 120301-B0602-35-01 1 Wash T2/T3 CNC Turning, SSLC Not Applicable CNC Operator Washing Equipment, MC 360 0.25 1 1 0.000 $0.00 $36.98 $49.38 $49.38 $0.00 $0.03 $0.14 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $0.00

8 120301-B0602-35-03 1

G Valve Plate, Base, Stamp

T2/T3 Stamp/Form, SSLC Not Applicable

Cut/Punch/Forming OperatorOEMFine blank, SS

1231 0.5 1 1 0.552 $0.00 $135.07 $124.83 $124.83 $0.00 $0.05 $0.10 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.17 $0.17 $0.00

9 120301-B0602-36-01 1 Wash T2/T3 CNC Turning, SSLC Not Applicable CNC Operator Washing Equipment, MC 360 0.25 1 1 0.000 $0.00 $36.98 $49.38 $49.38 $0.00 $0.03 $0.14 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $0.00

10 120301-B0602-36-03 1

G Valve Plate, Valve, Stamp

T2/T3 Stamp/Form, SSLC Not Applicable

Cut/Punch/Forming OperatorOEMFine blank, SS

3488 0.5 1 1 0.024 $0.00 $135.07 $124.83 $124.83 $0.00 $0.02 $0.04 $0.06 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.06 $0.06 $0.00

11 120301-B0602-37-01 1 Wash T2/T3 CNC Turning, SSLC Not Applicable CNC Operator Washing Equipment, MC 360 0.25 1 1 0.000 $0.00 $36.98 $49.38 $49.38 $0.00 $0.03 $0.14 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $0.00

12 120301-B0602-37-03 1

G Steel Valve, Top, Stamp

T2/T3 Stamp/Form, SSLC HC-Steel-1000S, Coil

Cut/Punch/Forming OperatorOEMFine blank, SS

3488 0.5 1 1 0.072 $0.65 $135.07 $124.83 $124.83 $0.05 $0.02 $0.04 $0.10 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.11 $0.11 $0.05

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

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

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

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 G Valve Plate, Pin 120301-B0602-38 4 s $0.00 $0.01 $0.00 $0.04 $0.04

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

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

Material

$0.18

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

Mark-up $1.96

T1 or OEM Total Manufacturing Cost: $0.18 $0.68 $0.92 $1.78 $0.01 $0.10 $0.07 $0.00 $0.18 $1.96

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub3

1

Notes: 

a) Items 1,2, & 3 must a

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 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-33/38 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

TOTAL COSTS

47 North America

450,000

1

450,000

T1 Moderate Assembly Complexity

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

9,574

10

TOOLING & INVESTMENT

North America

FOB Ship Point

MARK-UP COSTS Manufacturing Costs 

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

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

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 ----- ----- ----- $0.01 $0.13 $0.12 $0.05 $0.30

Base Cost Impact to Vehicle: $0.18 $0.68 $0.92 $1.78 $0.02 $0.23 $0.19 $0.05 $0.48 $2.27 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $2.27

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

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

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

a) Items 1,2, & 3 must a

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.)

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% 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

Part Size:

Parts/Layer:

Number of Layers:

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

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

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

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

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

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

File: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 6 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)

 G Steel Valve, AC Pump Front Cover 

120301-B0602-33

120301-B0602-33-01

120301-B0602-33-03

G Gasket, Front Cover

120301-B0602-39

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

$0.03 $0.14 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02 Washer Turbo Tunnel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 5 1 10 1.0 1.0

$0.02 $0.02 $0.08 $0.00 $0.00 $0.00 $0.00 $0.01

Stamping Press 200-400 Ton 

5 2 10 100 47 4700 96 37.60 85% 113 31.96 2 2 1 2 1.0 1.0

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

$0.01 $0.00 $0.06 $0.00 $0.00 $0.00 $0.00 $0.01

Stamping Press 0-60 Ton 

5 2 10 100 47 4700 96 37.60 85% 113 31.96 1 1 1 1 1.0 1.0

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

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity

120301-B0602-39

G Valve Plate, Front Cover

120301-B0602-34

120301-B0602-35-01

120301-B0602-35-03

120301-B0602-36-01

120301-B0602-36-03

120301-B0602-37-01

120301-B0602-37-03

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

$0.01 $0.00 $0.06 $0.00 $0.00 $0.00 $0.00 $0.01 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1 1 1 1 1.0 1.0

$0.46 $0.18 $0.64 $0.00 $0.04 $0.03 $0.00 $0.07 Low Complexity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 43.0 15 1 43.0 1.0 1.5

$0.03 $0.14 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02 Washer Turbo Tunnel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 14.0 5 1 10.0 1.0 1.0

$0.05 $0.10 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02

Stamping Press 200-400 Ton 

5 2 10 100 47 4700 96 37.60 85% 113 31.96 1.7 2 1 2.9 1.0 1.0

$0.03 $0.14 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02 Washer Turbo Tunnel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 14.0 5 1 10.0 1.0 1.0

$0.02 $0.04 $0.06 $0.00 $0.00 $0.00 $0.00 $0.01

Stamping Press 0-60 Ton 

5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.6 2 1 1.03 1.0 1.0

$0.03 $0.14 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02 Washer Turbo Tunnel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16.0 5 1 10.0 1.0 1.0

$0.02 $0.04 $0.10 $0.00 $0.01 $0.00 $0.00 $0.01

Stamping Press 0-60 Ton 

5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.6 2 1 1.03 1.0 1.0

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

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

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

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

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

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

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

G Valve Plate, Pin 120301-B0602-38 $0.04

$0.00

$0.00

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

Total

$0.68 $0.92 $1.78 $0.01 $0.10 $0.07 $0.00 $0.18

$1.96

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: 4 of 6 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 Project Process Requirement

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity

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: 5 of 6 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)

 G Steel Valve, AC Pump Front Cover 

120301-B0602-33

120301-B0602-33-01

120301-B0602-33-03

G Gasket, Front Cover

120301-B0602-39

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! -

360 10.00 0.25

2118 1.70 0.25

#DIV/0! #DIV/0!

120301-B0602-39 5143 0.70 0.25

G Valve Plate, Front Cover

120301-B0602-34

120301-B0602-35-01

120301-B0602-35-03

120301-B0602-36-01

120301-B0602-36-03

120301-B0602-37-01

120301-B0602-37-03

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

5143 0.70 0.25

126 28.67 1.50

360 10.00 0.25

1231 2.92 0.50

360 10.00 0.25

3488 1.03 0.50

360 10.00 0.25

3488 1.03 0.50

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

G Valve Plate, Pin 120301-B0602-38

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 6 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: 1 of 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-40 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

G Front Cover Asm.

120301-B0602-40

2 Assembly 120301-B0602-40-01 1 Assembly T1 Low Assembly Complexity Not Applicable

General Assembly Mech Assembly, LC, Base

195 2 1 2 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.40 $0.15 $0.55 0.30% 6.00% 4.00% 1.00% 11.30% $0.06 $0.61 $0.61 $0.00

3 1 Wash Cycles thru machining 120301-B0602-40-02 1 1 Wash Cycles thru machining Not Applicable Not Applicable CNC Operator Washing Equipment, LC 360 0.25 1 1 0.000 $0.00 $36.98 $10.75 $10.75 $0.00 $0.03 $0.03 $0.06 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.06 $0.06 $0.00

4 Machine 120301-B0602-40-03 1 Machine Not Applicable Not Applicable CNC Operator CNC Machining, LC 127 2.5 5 1 0.000 $0.00 $36.98 $30.38 $151.90 $0.00 $0.73 $1.20 $1.93 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.93 $1.93 $0.00

5 Heat Treat 120301-B0602-40-04 1 Heat Treat Not Applicable Not Applicable Heat Treat Operator T5-Al380, SMS 161 1.5 1 1 0.784 $0.01 $47.72 $10.17 $10.17 $0.01 $0.44 $0.06 $0.52 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.52 $0.52 $0.01

Costs Broken Out In

TOTAL COSTS

47 North America

450,000

1

450,000

T1 Moderate Assembly Complexity

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

9,574

10

TOOLING & INVESTMENT

North America

FOB Ship Point

MARK-UP COSTS Manufacturing Costs 

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

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

6 G Front Cover - Cast 120301-B0602-40-05 1 G Front Cover - Cast Not Applicable

Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, MS 295 1 1 1.1 0.784 $1.10 $41.48 $197.05 $216.76 $0.86 $0.14 $0.73 $1.74 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.74 $1.74 $0.86

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

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #REF! #REF! #REF! #REF! #REF! #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 #REF! #REF! #REF! #REF! #REF! #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

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 G Seal, Front Cover 120301-B0602-41 1 s $0.00 $0.65 $0.00 $0.65 $0.65

2 G Snap-ring, Seal Front Cover 120301-B0602-42 1 s $0.00 $0.07 $0.00 $0.07 $0.07

3 G Dust Seal, Cloth, Front Cover 120301-B0602-43 1 s $0.00 $0.01 $0.00 $0.01 $0.01

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

Material

$1.60

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

Mark-up $5.58

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

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

1

T1 or OEM Total Manufacturing Cost: $1.60 $1.73 $2.18 $5.52 $0.00 $0.03 $0.02 $0.01 $0.06 $5.58

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 $0.36 $0.33 $0.14 $0.86

Base Cost Impact to Vehicle: $1.60 $1.73 $2.18 $5.52 $0.03 $0.40 $0.36 $0.14 $0.93 $6.44 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $6.44

3

Notes: 

a) Items 1,2, & 3 must a

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: 2 of 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-40 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

TOTAL COSTS

47 North America

450,000

1

450,000

T1 Moderate Assembly Complexity

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

9,574

10

TOOLING & INVESTMENT

North America

FOB Ship Point

MARK-UP COSTS Manufacturing Costs 

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

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

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% 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: 3 of 6 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)

G Front Cover Asm.

120301-B0602-40

Assembly 120301-B0602-40-01

1 Wash Cycles thru machining 120301-B0602-40-02

Machine 120301-B0602-40-03

Heat Treat 120301-B0602-40-04

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

$0.40 $0.15 $0.55 $0.00 $0.03 $0.02 $0.01 $0.06 Low Complexity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 37 13 1 19 2.0 1.0

$0.03 $0.03 $0.06 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Type Washer, 5-10 minute cycle time Basket Size 15.75X18.5x25.5 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 5 1 10 1.0 1.0

$0.73 $1.20 $1.93 $0.00 $0.00 $0.00 $0.00 $0.00 EC-300-AL Horizontal CNC , Pallet Size 300 mm2 550 lb capacity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 149 60 1 142 1.0 5.0

$0.44 $0.06 $0.52 $0.00 $0.00 $0.00 $0.00 $0.00 T5 Heat treat 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - - 1,210 27,000 1.0 1.0

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

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity

G Front Cover - Cast 120301-B0602-40-05

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

G Seal, Front Cover 120301-B0602-41

G Snap-ring, Seal Front Cover 120301-B0602-42

G Dust Seal, Cloth, Front Cover 120301-B0602-43

$0.14 $0.73 $1.74 $0.00 $0.00 $0.00 $0.00 $0.00 Aluminum Diecasting, Medium 500-1000 Ton 1.1 Multiplier used for trim 

operations 5 2 10 100 47 4700 96 37.60 85% 113 31.96 12 2 4 49 1.1 1.0

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

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

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

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

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

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

$0.65

$0.07

$0.01

$0.00

$0.00

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

Total

$1.73 $2.18 $5.52 $0.00 $0.03 $0.02 $0.01 $0.06

$5.58

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: 4 of 6 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 Project Process Requirement

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity

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 6 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)

G Front Cover Asm.

120301-B0602-40

Assembly 120301-B0602-40-01

1 Wash Cycles thru machining 120301-B0602-40-02

Machine 120301-B0602-40-03

Heat Treat 120301-B0602-40-04

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

195 18.50 2.00

360 10.00 0.25

127 28.38 2.50

161 22.31 1.50

G Front Cover - Cast 120301-B0602-40-05

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

G Seal, Front Cover 120301-B0602-41

G Snap-ring, Seal Front Cover 120301-B0602-42

G Dust Seal, Cloth, Front Cover 120301-B0602-43

295 12.19 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! -

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 6 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: 1 of 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-44/48 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

G Steel Valve, AC Pump

120301-B0602-44 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 120301-B0602-44-01 1 In-Line Washer T2/T3 CNC Turning, SSLC Not Applicable CNC Operator Washing Equipment, MC 360 0.25 1 1 0.000 $0.00 $36.98 $49.38 $49.38 $0.00 $0.03 $0.14 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $0.00

3 120301-B0602-44-03 1 G Steel Valve,Stamp T2/T3 Stamp/Form, SSLC HC-Steel-1000S, Coil

Cut/Punch/Forming OperatorOEMStamp/Form, SS

2118 0.25 1 1 0.067 $0.65 $135.07 $42.91 $42.91 $0.04 $0.02 $0.02 $0.08 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.09 $0.09 $0.04

4

G Gasket, Rear Cover

120301-B0602-50 1

G Gasket, Stamp

T2/T3 Stamp/Form, SSLC HC-Steel-1000S, Coil

Cut/Punch/Forming OperatorOEMStamp/Form, Terminals

5143 0.25 1 1 0.080 $0.65 $135.07 $15.50 $15.50 $0.05 $0.01 $0.00 $0.06 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.07 $0.07 $0.05

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS

T1 Moderate Assembly Complexity

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

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)

5 G Valve Plate, Rear Cover 120301-B0602-45 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 120301-B0602-45-01 1 Assembly T2/T3 Mech. Assembly, SSLC Not Applicable

General Assembly Mech Assembly, LC, Base

116 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.33 $0.13 $0.46 0.30% 6.00% 4.00% 0.00% 10.30% $0.05 $0.51 $0.51 $0.00

7 G Valve Plate, Base 120301-B0602-46-01 1 Wash T2/T3 CNC Turning, SSLC Not Applicable CNC Operator Washing Equipment, MC 360 0.25 1 1 0.000 $0.00 $36.98 $49.38 $49.38 $0.00 $0.03 $0.14 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $0.00

8 120301-B0602-46-03 1

G Valve Plate, Base, Stamp

T2/T3 Stamp/Form, SSLC Not Applicable

Cut/Punch/Forming OperatorOEMFine blank, SS

6192 0.5 2.924 1 0.552 $0.00 $135.07 $42.91 $125.47 $0.00 $0.01 $0.02 $0.03 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.03 $0.03 $0.00

9 120301-B0602-47-01 1 Wash T2/T3 CNC Turning, SSLC Not Applicable CNC Operator Washing Equipment, MC 360 0.25 1 1 0.000 $0.00 $36.98 $49.38 $49.38 $0.00 $0.03 $0.14 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $0.00

10 120301-B0602-47-03 1

G Valve Plate, Valve, Stamp

T2/T3 Stamp/Form, SSLC HC-Steel-1000S, Coil

Cut/Punch/Forming OperatorOEMFine blank, SS

6192 0.5 1.032 1 0.024 $0.65 $135.07 $42.91 $44.28 $0.02 $0.01 $0.01 $0.03 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.04 $0.04 $0.02

11 120301-B0602-48-01 1 Wash T2/T3 CNC Turning, SSLC Not Applicable CNC Operator Washing Equipment, MC 360 0.25 1 1 0.000 $0.00 $36.98 $49.38 $49.38 $0.00 $0.03 $0.14 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $0.00

12 120301-B0602-48-03 1

G Steel Valve, Top, Stamp

T2/T3 Stamp/Form, SSLC HC-Steel-1000S, Coil

Cut/Punch/Forming OperatorOEMFine blank, SS

6192 0.5 1.032 1 0.072 $0.65 $135.07 $42.91 $44.28 $0.05 $0.01 $0.01 $0.06 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.07 $0.07 $0.05

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

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

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

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

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 G Valve Plate, Pin 120301-B0602-49 4 s $0.00 $0.01 $0.00 $0.04 $0.04 "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub1 G Valve Plate, Pin 120301-B0602-49 4 s $0.00 $0.01 $0.00 $0.04 $0.04

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

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

Material

$0.20

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

Mark-up $1.57

T1 or OEM Total Manufacturing Cost: $0.20 $0.49 $0.74 $1.42 $0.00 $0.08 $0.06 $0.00 $0.14 $1.57

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

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub3

1

Notes: 

a) Items 1,2, & 3 must a

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 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-44/48 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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS

T1 Moderate Assembly Complexity

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

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)

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.10 $0.09 $0.04 $0.24

Base Cost Impact to Vehicle: $0.20 $0.49 $0.74 $1.42 $0.01 $0.18 $0.15 $0.04 $0.39 $1.81 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $1.81

Packaging 

Cost per Total Lump Sum Payment Total # of Number of Interest 

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:

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 Cost per 

Piece

Total 

Amount 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% 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

Parts/Layer:

Number of Layers:

Assume Plastic Returnables Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

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

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

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

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

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

File: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 6 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)

G Steel Valve, AC Pump

120301-B0602-44

120301-B0602-44-01

120301-B0602-44-03

G Gasket, Rear Cover

120301-B0602-50

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

$0.03 $0.14 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02 Washer Turbo Tunnel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 5 1 10 1.0 1.0

$0.02 $0.02 $0.08 $0.00 $0.00 $0.00 $0.00 $0.01

Stamping Press 200-400 Ton 

5 2 10 100 47 4700 96 37.60 85% 113 31.96 x 1.7 2 1.0 1.7 1.0 1.0

$0.01 $0.00 $0.06 $0.00 $0.00 $0.00 $0.00 $0.01

Stamping Press 0-60 Ton 

5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.7 2 1.0 0.7 1.0 1.0

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

Projected Operating Pattern Minimum Calculated Cycles Time 

G Valve Plate, Rear Cover 120301-B0602-45

120301-B0602-45-01

G Valve Plate, Base 120301-B0602-46-01

120301-B0602-46-03

120301-B0602-47-01

120301-B0602-47-03

120301-B0602-48-01

120301-B0602-48-03

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

G Valve Plate, Pin 120301-B0602-49

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

$0.33 $0.13 $0.46 $0.00 $0.03 $0.02 $0.00 $0.05 Low Complexity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 31 15 1 31.0 1.0 1.0

$0.03 $0.14 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02 Washer Turbo Tunnel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 14 5 1 10.0 1.0 1.0

$0.01 $0.02 $0.03 $0.00 $0.00 $0.00 $0.00 $0.00

Stamping Press 200-400 Ton 

5 2 10 100 47 4700 96 37.60 85% 113 31.96 2 2 1 1.7 1.0 2.9

$0.03 $0.14 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02 Washer Turbo Tunnel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 14 5 1 10.0 1.0 1.0

$0.01 $0.01 $0.03 $0.00 $0.00 $0.00 $0.00 $0.00

Stamping Press 0-60 Ton 

5 2 10 100 47 4700 96 37.60 85% 113 31.96 1 2 1 0.6 1.0 1.03

$0.03 $0.14 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02 Washer Turbo Tunnel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 5 1 10.0 1.0 1.0

$0.01 $0.01 $0.06 $0.00 $0.00 $0.00 $0.00 $0.01

Stamping Press 0-60 Ton 

5 2 10 100 47 4700 96 37.60 85% 113 31.96 1 2 1 0.6 1.0 1.03

$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

G Valve Plate, Pin 120301-B0602-49 $0.04

$0.00

$0.00

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

Total

$0.49 $0.74 $1.42 $0.00 $0.08 $0.06 $0.00 $0.14

$1.57

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: 4 of 6 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

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

Projected Operating Pattern Minimum Calculated Cycles Time 

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 6 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)

G Steel Valve, AC Pump

120301-B0602-44

120301-B0602-44-01

120301-B0602-44-03

G Gasket, Rear Cover

120301-B0602-50

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! -

360 10.00 0.25

2118 1.70 0.25

5143 0.70 0.25

G Valve Plate, Rear Cover 120301-B0602-45

120301-B0602-45-01

G Valve Plate, Base 120301-B0602-46-01

120301-B0602-46-03

120301-B0602-47-01

120301-B0602-47-03

120301-B0602-48-01

120301-B0602-48-03

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

G Valve Plate, Pin 120301-B0602-49

#DIV/0! #DIV/0! -

116 31.00 1.00

360 10.00 0.25

6192 0.58 0.50

360 10.00 0.25

6192 0.58 0.50

360 10.00 0.25

6192 0.58 0.50

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

G Valve Plate, Pin 120301-B0602-49

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 6 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: 1 of 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-051 Weekly Component Volume: Packaging Specification: Retrunable 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

G Rear Cover Asm

120301-B0602-51 0

2 Assembly 120301-B0602-51-01 1 Assembly T1 Low Assembly Complexity Not Applicable

General Assembly Mech Assembly, LC, Base

157 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.25 $0.10 $0.34 0.30% 6.00% 4.00% 1.00% 11.30% $0.04 $0.38 $0.38 $0.00

3 Batch Type Washer 120301-B0602-51-02 1 Batch Type Washer Not Applicable Not Applicable CNC Operator Washing Equipment, LC 360 0.25 1 1 0.000 $0.00 $36.98 $10.75 $10.75 $0.00 $0.03 $0.03 $0.06 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.06 $0.06 $0.00

4 Machine 120301-B0602-51-03 1 Machine Not Applicable Not Applicable CNC Operator CNC Machining, LC 113 2 4 1 0.000 $0.00 $36.98 $30.38 $121.52 $0.00 $0.66 $1.08 $1.74 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.74 $1.74 $0.00

Heat Treat 120301-B0602-51-04 1 Heat Treat Not Applicable Not Applicable Heat Treat Operator T5-Al380, SMS 300 1.5 1 1 0.884 $0.01 $47.72 $10.17 $10.17 $0.01 $0.24 $0.03 $0.28 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.28 $0.28 $0.01

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

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

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

5 G Rear Cover, Casting 120301-B0602-51-05 1 G Rear Cover, Casting Not Applicable Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LMC 435 1 1 1.1 0.884 $1.10 $41.48 $116.73 $128.40 $0.97 $0.10 $0.30 $1.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.36 $1.36 $0.97

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

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

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

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

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 G O-ring, Plug, Rear Cover 120301-B0602-52 1 s $0.00 $0.01 $0.00 $0.01 $0.01

2 G Plug Asm. , Rear Cover 120301-B0602-53 1 s $0.00 $0.65 $0.00 $0.65 $0.65

3 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

Material

$1.64

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

Mark-up $4.48

T1 or OEM Total Manufacturing Cost: $1.64 $1.26 $1.53 $4.44 $0.00 $0.02 $0.01 $0.00 $0.04 $4.48

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

3

1

Notes: 

T1 or OEM Mark-Up Rates: a) Items 1,2, & 3 must a----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.02 $0.29 $0.27 $0.11 $0.69

Base Cost Impact to Vehicle: $1.64 $1.26 $1.53 $4.44 $0.02 $0.31 $0.28 $0.12 $0.73 $5.17 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $5.17

a) Items 1,2, & 3 must a

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: 2 of 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-051 Weekly Component Volume: Packaging Specification: Retrunable 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

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

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% 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: 3 of 6 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)

G Rear Cover Asm

120301-B0602-51

Assembly 120301-B0602-51-01

Batch Type Washer 120301-B0602-51-02

Machine 120301-B0602-51-03

Heat Treat 120301-B0602-51-04

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

$0.25 $0.10 $0.34 $0.00 $0.02 $0.01 $0.00 $0.04 Low Complexity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 23 7 1 23 1.0 1.0

$0.03 $0.03 $0.06 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Type Washer, 5-10 minute cycle time Basket Size 15.75X18.5x25.5 5 2 10 100 47 4700 96 37.60 85% 113 31.96 14 5 1 10 1.0 1.0

$0.66 $1.08 $1.74 $0.00 $0.00 $0.00 $0.00 $0.00 EC-300-AL Horizontal CNC , Pallet Size 300 mm2 550 lb capacity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 135 54 1 128 1.0 4.0

$0.24 $0.03 $0.28 $0.00 $0.00 $0.00 $0.00 $0.00 T5 Heat treat 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - - 2,250 27,000 1.0 1.0

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

Projected Operating Pattern Minimum Calculated Cycles Time 

G Rear Cover, Casting 120301-B0602-51-05

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

G O-ring, Plug, Rear Cover 120301-B0602-52

G Plug Asm. , Rear Cover 120301-B0602-53

$0.10 $0.30 $1.36 $0.00 $0.00 $0.00 $0.00 $0.00 Aluminum Diecasting, Medium 500-1000 Ton 1.1 Multiplier for trim operations 5 2 10 100 47 4700 96 37.60 85% 113 31.96 8 2 4 33 1.1 1.0

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

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

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

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

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

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

$0.01

$0.65

$0.00

$0.00

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

Total

$1.26 $1.53 $4.44 $0.00 $0.02 $0.01 $0.00 $0.04

$4.48

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: 4 of 6 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

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

Projected Operating Pattern Minimum Calculated Cycles Time 

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 6 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)

G Rear Cover Asm

120301-B0602-51

Assembly 120301-B0602-51-01

Batch Type Washer 120301-B0602-51-02

Machine 120301-B0602-51-03

Heat Treat 120301-B0602-51-04

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 -

157 23.00 1.00

360 10.00 0.25

113 31.98 2.00

300 12.00 1.50

G Rear Cover, Casting 120301-B0602-51-05

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

G O-ring, Plug, Rear Cover 120301-B0602-52

G Plug Asm. , Rear Cover 120301-B0602-53

435 8.28 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! -

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 6 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: 1 of 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-054 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 Labor

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

1

G Magnet Asm., AC Clutch

120301-B0602-54 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00 $0.00

2 120301-B0602-54-01 1 Assembly T1 Low Assembly Complexity Not Applicable

Welding/Soldering Operator Mech Assembly, LC, Base

176 2 1 2 0.000 $0.00 $41.55 $15.00 $30.00 $0.00 $0.47 $0.17 $0.64 0.30% 6.00% 4.00% 1.00% 11.30% $0.07 $0.72 $0.72 $0.00 $0.47

3 120301-B0602-54-02 1 Paint T1 Low Assembly Complexity Not Applicable

Welding/Soldering Operator Mech Assembly, LC, Base

720 1 1 10 0.000 $0.00 $41.55 $15.00 $150.00 $0.00 $0.06 $0.21 $0.27 0.30% 6.00% 4.00% 1.00% 11.30% $0.03 $0.30 $0.30 $0.00 $0.06

4 120301-B0602-54-03 1 Put Wire Coil in Housing T1 Low Assembly Complexity Not Applicable

Welding/Soldering Operator Mech Assembly, LC, Base

88 1 1 1 0.000 $0.00 $41.55 $15.00 $15.00 $0.00 $0.47 $0.17 $0.64 0.30% 6.00% 4.00% 1.00% 11.30% $0.07 $0.72 $0.72 $0.00 $0.47

Costs Broken Out Into 

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs x 

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)

4 120301-B0602-54-03 1 Put Wire Coil in Housing T1 Low Assembly Complexity Not Applicable 88 1 1 1 0.000 $0.00 $41.55 $15.00 $15.00 $0.00 $0.47 $0.17 $0.64 0.30% 6.00% 4.00% 1.00% 11.30% $0.07 $0.72 $0.72 $0.00 $0.47

5 G Magnet Coil 120301-B0602-54-04 1 G Magnet Coil, Solder ConnectorT2/T3 Mech. Assembly, SSLC Not Applicable

Welding/Soldering Operator Mech Assembly, LC, Base

138 1 1 1 0.000 $0.00 $41.55 $15.00 $15.00 $0.00 $0.30 $0.11 $0.41 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.45 $0.45 $0.00 $0.30

6 120301-B0602-54-05 1 G Magnet Coil, Wind T2/T3 Mech. Assembly, SSLC

Copper-Pure, Wire Welding/Soldering Operator Mech Assembly, LC, Base

257 1 1 1 0.900 $2.45 $41.55 $15.00 $15.00 $2.21 $0.16 $0.06 $2.42 0.30% 6.00% 4.00% 0.00% 10.30% $0.25 $2.67 $2.67 $2.21 $0.16

7 120301-B0602-54-06 1 G Housing Asm, Wash T2/T3 CNC Turning, SSLC Not Applicable CNC Operator Washing Equipment, MC 360 0.25 1 1 0.000 $0.00 $36.98 $49.38 $49.38 $0.00 $0.03 $0.14 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $0.00 $0.03

8 120301-B0602-54-07 1 Weld Housing to Backing Plate T2/T3 Mech. Assembly, SSLC Not Applicable

Welding/Soldering Operator Mech Assembly, LC, Base

106 1 1 1 0.000 $0.00 $41.55 $15.00 $15.00 $0.00 $0.39 $0.14 $0.53 0.30% 6.00% 4.00% 0.00% 10.30% $0.06 $0.59 $0.59 $0.00 $0.39

9 G Housing, 120301-B0602-54-08 1 G Housing, Wash T2/T3 CNC Turning, SSLC Not Applicable CNC Operator Washing Equipment, MC 360 0.25 1 1 0.000 $0.00 $36.98 $49.38 $49.38 $0.00 $0.03 $0.14 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $0.00 $0.03

10 120301-B0602-54-09 1 G Housing, Debur T2/T3 CNC Turning, SSLC Not Applicable Grinding/Polishing Operator Grinding, SS 327 0.25 1 1 0.000 $0.00 $42.14 $45.00 $45.00 $0.00 $0.03 $0.14 $0.17 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.19 $0.19 $0.00 $0.03

11 120301-B0602-54-10 1 G Housing, Machine T2/T3 CNC Turning, SSLC Not Applicable CNC Operator CNC Turning, MLS, BF, DA 212 1 1 1 0.000 $0.00 $36.98 $32.88 $32.88 $0.00 $0.17 $0.16 $0.33 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.36 $0.36 $0.00 $0.17

12 120301-B0602-54-11 1 G Housing, Stamp T2/T3 Stamp/Form, SSLC HC-Steel-1000S, Coil

Cut/Punch/Forming OperatorOEMStamp/Form, Terminals

6000 1 1 1 1.665 $0.65 $135.07 $15.50 $15.50 $1.08 $0.02 $0.00 $1.11 0.30% 6.00% 4.00% 0.00% 10.30% $0.11 $1.22 $1.22 $1.08 $0.02

13 G Backing Plate, 120301-B0602-54-12 1 G Backing Plate, Wash T2/T3 CNC Turning, SSLC Not Applicable CNC Operator Washing Equipment, MC 360 0.25 1 1 0.000 $0.00 $36.98 $49.38 $49.38 $0.00 $0.03 $0.14 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $0.00 $0.03

14 120301-B0602-54-13 1 G Backing Plate, Debur T2/T3 CNC Turning, SSLC Not Applicable Grinding/Polishing Operator Grinding, SS 327 0.25 1 1 0.000 $0.00 $42.14 $45.00 $45.00 $0.00 $0.03 $0.14 $0.17 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.19 $0.19 $0.00 $0.03

15 120301-B0602-54-14 1 G Backing Plate, Stamp T2/T3 Stamp/Form, SSLC HC-Steel-1000S, Coil

Cut/Punch/Forming OperatorOEMStamp/Form, Terminals

6000 1 1 1 0.341 $0.65 $135.07 $15.50 $15.50 $0.22 $0.02 $0.00 $0.25 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.27 $0.27 $0.22 $0.02

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 $0.00

33 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $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 $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 $0.00

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

1 G Magnet Asm, Liner 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00 $0.00

2 120301-B0602-58 1 Mold T2/T3 Inject. Mold, SSLC ABS Mold/Cast/Sinter Operator Inject. Mold, SS 4099 1 1 1 0.023 $0.72 $41.48 $16.39 $16.39 $0.02 $0.01 $0.00 $0.03 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.03 $0.03 $0.02 $0.01

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 $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 $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 G Snap-ring, AC Magnet 120301-B0602-55 1 s $0.00 $0.08 $0.00 $0.08 $0.08

2 G Magnet Asm, Pigtail Connector 120301-B0602-56 1 s $0.00 $0.45 $0.00 $0.45 $0.45

3 G Magnet Asm, Connector 120301-B0602-57 1 s $0.00 $0.08 $0.00 $0.08 $0.08

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 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 

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 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-054 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 Labor

Costs Broken Out Into 

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs x 

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)

Material Labor

$4.14 $2.23

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

Mark-up $8.86

T1 or OEM Total Manufacturing Cost: $4.14 $2.23 $1.71 $8.07 $0.02 $0.45 $0.30 $0.02 $0.78 $8.86

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 ----- ----- ----- $0.04 $0.58 $0.53 $0.22 $1.37

Base Cost Impact to Vehicle: $4.14 $2.23 $1.71 $8.07 $0.07 $1.02 $0.83 $0.24 $2.16 $10.23 $0 $0

Packaging Cost: $0.00

3

1

Notes: 

a) Items 1,2, & 3 must all e

Net Cost Impact to Vehicle: $10.23

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% 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

Packaging Cost Total: $0.000

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

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

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

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

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

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

File: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 6 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)

G Magnet Asm., AC Clutch

120301-B0602-54

120301-B0602-54-01

120301-B0602-54-02

120301-B0602-54-03

GENERAL COMPONENT INFORMATION

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

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

Resulting Pieces/Hour

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

$0.17 $0.64 $0.00 $0.04 $0.03 $0.01 $0.07 Low Complexity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 41 2 1 21 2.0 1.0 176

$0.21 $0.27 $0.00 $0.02 $0.01 $0.00 $0.03

Spray Tool

5 2 10 100 47 4700 96 37.60 85% 113 31.96 48 5 1 5 10.0 1.0 720

$0.17 $0.64 $0.00 $0.04 $0.03 $0.01 $0.07 Low Complexity Assembly 5 2 10 100 47 4700 96 37.60 85% 113 31.96 41 13 1 41 1.0 1.0 88

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

120301-B0602-54-03

G Magnet Coil 120301-B0602-54-04

120301-B0602-54-05

120301-B0602-54-06

120301-B0602-54-07

G Housing, 120301-B0602-54-08

120301-B0602-54-09

120301-B0602-54-10

120301-B0602-54-11

G Backing Plate, 120301-B0602-54-12

120301-B0602-54-13

120301-B0602-54-14

Purchase Part - High Impact Item (Full Cost Mapping)

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

G Magnet Asm, Liner

120301-B0602-58

$0.17 $0.64 $0.00 $0.04 $0.03 $0.01 $0.07 Low Complexity Assembly 5 2 10 100 47 4700 96 37.60 85% 113 31.96 41 13 1 41 1.0 1.0 88

$0.11 $0.41 $0.00 $0.02 $0.02 $0.00 $0.04

Flux, Solder

5 2 10 100 47 4700 96 37.60 85% 113 31.96 26 7 1 26 1.0 1.0 138

$0.06 $2.42 $0.01 $0.15 $0.10 $0.00 $0.25 Copper wire 0.8 mm (20 AWG), 5 2 10 100 47 4700 96 37.60 85% 113 31.96 14 355 1 14 1.0 1.0 257

$0.14 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02 In Line Washer 5 2 10 100 47 4700 96 37.60 85% 113 31.96 12 5 1 10 1.0 1.0 360

$0.14 $0.53 $0.00 $0.03 $0.02 $0.00 $0.06

Spot Weld

5 2 10 100 47 4700 96 37.60 85% 113 31.96 34 12 1 34 1.0 1.0 106

$0.14 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02 In Line Washer 5 2 10 100 47 4700 96 37.60 85% 113 31.96 12 5 1 10 1.0 1.0 360

$0.14 $0.17 $0.00 $0.01 $0.01 $0.00 $0.02 Tumble 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 5 1 11 1.0 1.0 327

$0.16 $0.33 $0.00 $0.02 $0.01 $0.00 $0.03 CNC Turning 2 Axis SL-40, 4" bar 5 2 10 100 47 4700 96 37.60 85% 113 31.96 17 10 1 17 1.0 1.0 212

$0.00 $1.11 $0.00 $0.07 $0.04 $0.00 $0.11

Stamping Press 0-60 Ton 

2 2 10 40 47 1880 239 15.04 85% 282 12.78 1 2 1 1 1.0 1.0 6000

$0.14 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02 In Line Washer 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 5 1 10 1.0 1.0 360

$0.14 $0.17 $0.00 $0.01 $0.01 $0.00 $0.02 Tumble 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 5 1 11 1.0 1.0 327

$0.00 $0.25 $0.00 $0.01 $0.01 $0.00 $0.03

Stamping Press 0-60 Ton 

5 2 10 100 47 4700 96 37.60 85% 113 31.96 1 2 1 1 1.0 1.0 6000

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

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

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

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

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

$0.00 $0.03 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1 1 6 5 1.0 1.0 4099

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

G Snap-ring, AC Magnet 120301-B0602-55

G Magnet Asm, Pigtail Connector 120301-B0602-56

G Magnet Asm, Connector 120301-B0602-57

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

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

$0.08

$0.45

$0.08

$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: 4 of 6 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.

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

Resulting Pieces/Hour

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

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

Total

$1.71 $8.07 $0.02 $0.45 $0.30 $0.02 $0.78

$8.86

2

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: 5 of 6 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)

G Magnet Asm., AC Clutch

120301-B0602-54

120301-B0602-54-01

120301-B0602-54-02

120301-B0602-54-03

GENERAL COMPONENT INFORMATION

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

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! -

20.50 2.00

1.00 1.00

120301-B0602-54-03 41.00 1.00

G Magnet Coil 120301-B0602-54-04

120301-B0602-54-05

120301-B0602-54-06

120301-B0602-54-07

G Housing, 120301-B0602-54-08

120301-B0602-54-09

120301-B0602-54-10

120301-B0602-54-11

G Backing Plate, 120301-B0602-54-12

120301-B0602-54-13

120301-B0602-54-14

Purchase Part - High Impact Item (Full Cost Mapping)

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

G Magnet Asm, Liner

120301-B0602-58

41.00 1.00

26.00 1.00

14.00 1.00

10.00 0.25

34.00 1.00

10.00 0.25

11.00 0.25

17.00 1.00

0.60 1.00

10.00 0.25

11.00 0.25

0.60 1.00

#DIV/0! -

#DIV/0! -

#DIV/0! -

#DIV/0! -

#DIV/0! -

0.88 1.00

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

G Snap-ring, AC Magnet 120301-B0602-55

G Magnet Asm, Pigtail Connector 120301-B0602-56

G Magnet Asm, Connector 120301-B0602-57

#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: 6 of 6 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 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: 1 of 9 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-059 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

G Clutch Hub Asm.

120301-B0602-59 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 Assembly 120301-B0602-59-01 1 Assembly T2/T3 Mech. Assembly, SSLC Not Applicable

General Assembly Mech Assembly, LC, Base

59 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.65 $0.25 $0.91 0.30% 6.00% 4.00% 0.00% 10.30% $0.09 $1.00 $1.00 $0.00

5 G Clutch Hub, Isolator,Painted, Asm 120301-B0602-66 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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

Paint Oven Cure General Assembly Mech Assembly, LC, Base

Costs Broken Out In

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

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)

5 120301-B0602-66-01 1

Paint Oven Cure

T2/T3 Mech. Assembly, SSLC Not Applicable

General Assembly Mech Assembly, LC, Base

152 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.06 $0.10 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $0.00

6 120301-B0602-66-02 1 Assembly T2/T3 Mech. Assembly, SSLC Not Applicable

General Assembly Mech Assembly, LC, Base

327 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.12 $0.05 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $0.00

7 G Clutch Hub, Isolator, SBR 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 120301-B0602-66-03 1 Load/unload T2/T3 Mech. Assembly, SSLC Not Applicable

General Assembly Mech Assembly, LC, Base

720 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.03 $0.02 $0.05 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.05 $0.05 $0.00

9 120301-B0602-66-04 1

G Clutch Hub, Isolator, 

SBR, Mold T2/T3 Inject. Mold, SSLC

PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, LS 1200 0.5 1 1 0.081 $1.46 $41.48 $151.77 $151.77 $0.12 $0.02 $0.13 $0.26 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.29 $0.29 $0.12

10 G Clutch Hub, Isolator, Outer 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 120301-B0602-66-05 1 In-Line Washer T2/T3 CNC Turning, SSLC Not Applicable CNC Operator Washing Equipment, LC 360 0.25 1 1 0.000 $0.00 $36.98 $10.75 $10.75 $0.00 $0.03 $0.03 $0.06 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.06 $0.06 $0.00

12 120301-B0602-66-06 1

Debur

T2/T3 CNC Turning, SSLC Not Applicable Grinding/Polishing OperatorGrinding, SS 327 0.25 1 1 0.000 $0.00 $42.14 $45.00 $45.00 $0.00 $0.03 $0.14 $0.17 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.19 $0.19 $0.00

13 120301-B0602-66-07 1

G Clutch Hub, Isolator, 

Outer, Stamped T2/T3 Stamp/Form, SSLC HC-Steel-1000S, Coil

Cut/Punch/Forming OperatorOEMStamp/Form, XSS

5143 0.25 1 1 0.307 $0.65 $135.07 $24.60 $24.60 $0.20 $0.01 $0.00 $0.21 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.23 $0.23 $0.20

14 G Clutch Hub, Isolator, Inner 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 120301-B0602-66-08 1 In-Line Washer T2/T3 CNC Turning, SSLC Not Applicable CNC Operator Washing Equipment, LC 360 0.25 1 1 0.000 $0.00 $36.98 $10.75 $10.75 $0.00 $0.03 $0.03 $0.06 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.06 $0.06 $0.00

16 120301-B0602-66-09 1

Debur

T2/T3 CNC Turning, SSLC Not Applicable Grinding/Polishing OperatorGrinding, SS 327 0.25 1 1 0.000 $0.00 $42.14 $45.00 $45.00 $0.00 $0.03 $0.14 $0.17 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.19 $0.19 $0.00

17 120301-B0602-66-10 1 Combo Tool Used: Drill & Tap T2/T3 CNC Turning, SSLC Not Applicable CNC Operator CNC Turning, SS, BF, DA 100 0.25 1 1 0.000 $0.00 $36.98 $20.48 $20.48 $0.00 $0.09 $0.20 $0.30 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.33 $0.33 $0.00

18 120301-B0602-66-11 1

G Clutch Hub, Isolator, 

Inner, Stamped T2/T3 Stamp/Form, SSLC HC-Steel-1000S, Coil

Cut/Punch/Forming OperatorOEMStamp/Form, XSS

5143 0.25 1 1 0.242 $0.65 $135.07 $24.60 $24.60 $0.16 $0.01 $0.00 $0.17 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.19 $0.19 $0.16

19 G Clutch Hub, Face 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 120301-B0602-65-01 1

Paint Oven Cure

T2/T3 Mech. Assembly, SSLC Not Applicable

General Assembly Mech Assembly, LC, Base

152 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.06 $0.10 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $0.00

22 120301-B0602-65-02 1 In-Line Washer T2/T3 CNC Turning, SSLC Not Applicable CNC Operator Washing Equipment, MC 360 0.25 1 1 0.000 $0.00 $36.98 $49.38 $49.38 $0.00 $0.03 $0.14 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $0.00

23 120301-B0602-65-03 1 Debur T2/T3 CNC Turning, SSLC Not Applicable Grinding/Polishing Operator Grinding, SS 327 0.25 1 1 0.000 $0.00 $42.14 $45.00 $45.00 $0.00 $0.03 $0.14 $0.17 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.19 $0.19 $0.00

24 120301-B0602-65-04 1 Counterbore Rivet Relief T2/T3 CNC Turning, SSLC Not Applicable CNC Operator CNC Turning, SS, BF, DA 150 1 1 1 0.000 $0.00 $36.98 $20.48 $20.48 $0.00 $0.25 $0.14 $0.38 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.42 $0.42 $0.00

25 120301-B0602-65-05 1 G Clutch Hub, Face, StampT2/T3 Stamp/Form, SSLC Not Applicable

Cut/Punch/Forming OperatorOEMStamp/Form, XSS

1800 1 1 1 1.167 $0.00 $135.07 $24.60 $24.60 $0.00 $0.08 $0.01 $0.09 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.10 $0.10 $0.00 OEM

26 G Clutch Hub, Splined Hub Not Applicable ##### 0 1 1 0.000 $0.00 #N/A #N/A #N/A $0.00 #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 120301-B0602-64-01 1

Paint Part Small

T2/T3 Mech. Assembly, SSLC Not Applicable

General Assembly Mech Assembly, LC, Base

152 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.06 $0.10 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $0.00

28 120301-B0602-64-02 1 In-Line Washer T2/T3 CNC Turning, SSLC Not Applicable CNC Operator Washing Equipment, MC 360 0.25 1 1 0.000 $0.00 $36.98 $49.38 $49.38 $0.00 $0.03 $0.14 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $0.00

29 120301-B0602-64-03 1 Bar Feed T2/T3 CNC Turning, SSLC MC-Steel-1018, Bar CNC Operator CNC Turning, SS, BF, DA 389 1 1 1 0.523 $0.74 $36.98 $20.48 $20.48 $0.39 $0.10 $0.05 $0.53 0.30% 6.00% 4.00% 0.00% 10.30% $0.06 $0.59 $0.59 $0.39

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

31 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

32 K G Outer AC Clutch Hub 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

33 G cover, AC Clutch Hub 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

34 120301-B0602-67-01 1 G cover, AC Clutch Hub T2/T3 Inject. Mold, SSLC PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, LS 1029 1 1 1 0.147 $1.46 $41.48 $151.77 $151.77 $0.21 $0.04 $0.15 $0.40 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.44 $0.44 $0.21

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 9 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-059 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

Electrically Versus Mechanically Driven Air Conditioning Compressor

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)

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

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

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 

Purchase 

Price/ 

Purchase 

Price Net, 

Purchase 

D Purchase Part - Commodity ( Value taken from Purchase Part Database) Account Price Net, 

Cost

Price/ 

Unit

Price Net, 

PIA

Price Net, 

End Item

1 1A G Clutch Hub, Rivet Pin, M6 120301-B0602-60 3 s $0.00 $0.01 $0.00 $0.02 $0.02

2 2A G Clutch Hub, Washer, M5 120301-B0602-61 3 s $0.00 $0.00 $0.00 $0.01 $0.01

3 3A G Clutch Hub, Rivet Pin, M5 120301-B0602-62 3 s $0.00 $0.01 $0.00 $0.02 $0.02

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

Material

$1.11

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

Mark-up $3.29

T1 or OEM Total Manufacturing Cost: $1.11 $1.77 $2.05 $4.94 $0.01 $0.29 $0.20 $0.00 $0.50 $5.44

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 $0.35 $0.33 $0.14 $0.84

Base Cost Impact to Vehicle: $1.11 $1.77 $2.05 $4.94 $0.04 $0.65 $0.52 $0.14 $1.35 $6.28 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $6.28

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

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

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

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

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

S. 020909)

Cost per Pallet /Rack

Total Number of Pallets/

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

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

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

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

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

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

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

File: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 9 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-059 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

Electrically Versus Mechanically Driven Air Conditioning Compressor

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)

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: 4 of 9 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)

G Clutch Hub Asm.

120301-B0602-59

Assembly 120301-B0602-59-01

G Clutch Hub, Isolator,Painted, Asm 120301-B0602-66

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

$0.65 $0.25 $0.91 $0.00 $0.05 $0.04 $0.00 $0.09 Low complexity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 61 16 1 61 1.0 1.0

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

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

Batch part, Paint Oven Cure

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

120301-B0602-66-01

120301-B0602-66-02

G Clutch Hub, Isolator, SBR

120301-B0602-66-03

120301-B0602-66-04

G Clutch Hub, Isolator, Outer

120301-B0602-66-05

120301-B0602-66-06

120301-B0602-66-07

G Clutch Hub, Isolator, Inner

120301-B0602-66-08

120301-B0602-66-09

120301-B0602-66-10

120301-B0602-66-11

G Clutch Hub, Face

120301-B0602-65-01

120301-B0602-65-02

120301-B0602-65-03

120301-B0602-65-04

120301-B0602-65-05

$0.06 $0.10 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02

Batch part, Paint Oven Cure

5 2 10 100 47 4700 96 37.60 85% 113 31.96 71 7 3 71 1.0 1.0

$0.12 $0.05 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02 Low complexity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 4 1 11 1.0 1.0

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

$0.03 $0.02 $0.05 $0.00 $0.00 $0.00 $0.00 $0.00 Low complexity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 5 1 1 5 1.0 1.0

$0.02 $0.13 $0.26 $0.00 $0.02 $0.01 $0.00 $0.03 6 Cavity Mold, Box Size 83mm Diam x 13mm H

5 2 10 100 47 4700 96 37.60 85% 113 31.96 3 1 6 18 1.0 1.0

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

$0.03 $0.03 $0.06 $0.00 $0.00 $0.00 $0.00 $0.01 Batch & Individual Washing with specialized spray nozzles 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 10 1.0 1.0

$0.03 $0.14 $0.17 $0.00 $0.01 $0.01 $0.00 $0.02 CNC Turning, General, Station Based with multiplier for added complexity over 

base assumptions. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 1 1 11 1.0 1.0

$0.01 $0.00 $0.21 $0.00 $0.01 $0.01 $0.00 $0.02

Stamping Press 0-60 Ton 

5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.7 1 1 0.7 1.0 1.0

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

$0.03 $0.03 $0.06 $0.00 $0.00 $0.00 $0.00 $0.01 Batch & Individual Washing with specialized spray nozzles 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 10 1.0 1.0

$0.03 $0.14 $0.17 $0.00 $0.01 $0.01 $0.00 $0.02 CNC Turning, General, Station Based with multiplier for added complexity over 

base assumptions. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 1 1 11 1.0 1.0

$0.09 $0.20 $0.30 $0.00 $0.02 $0.01 $0.00 $0.03 CNC Turning 2 Axis SL-10, Odd 5 2 10 100 47 4700 96 37.60 85% 113 31.96 36 1 1 36 1.0 1.0

$0.01 $0.00 $0.17 $0.00 $0.01 $0.01 $0.00 $0.02

Stamping Press 0-60 Ton 

5 2 10 100 47 4700 96 37.60 85% 113 31.96 1 1 1 1 1.0 1.0

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

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

$0.06 $0.10 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02

Batch part, Paint Oven Cure

5 2 10 100 47 4700 96 37.60 85% 113 31.96 71 1 3 71 1.0 1.0

$0.03 $0.14 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02 Batch & Individual Washing with specialized spray nozzles 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 10 1.0 1.0

$0.03 $0.14 $0.17 $0.00 $0.01 $0.01 $0.00 $0.02 CNC Turning 2 Axis SL-10, Odd 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 1 1 11 1.0 1.0

$0.25 $0.14 $0.38 $0.00 $0.02 $0.02 $0.00 $0.04 CNC Turning 2 Axis SL-10, Odd 5 2 10 100 47 4700 96 37.60 85% 113 31.96 24 1 1 24 1.0 1.0

$0.08 $0.01 $0.09 $0.00 $0.01 $0.00 $0.00 $0.01

Stamping Press 0-60 Ton 

5 2 10 100 47 4700 96 37.60 85% 113 31.96 2 1 1 2 1.0 1.0

G Clutch Hub, Splined Hub

120301-B0602-64-01

120301-B0602-64-02

120301-B0602-64-03

K G Outer AC Clutch Hub

G cover, AC Clutch Hub

120301-B0602-67-01

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

$0.06 $0.10 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02

Batch part, Paint Oven Cure

5 2 10 100 47 4700 96 37.60 85% 113 31.96 71 1 3 71 1.0 1.0

$0.03 $0.14 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02 Batch Type Washer, 5-10 minute cycle time Basket Size 15.75X18.5x25.5 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 10 1.0 1.0

$0.10 $0.05 $0.53 $0.00 $0.03 $0.02 $0.00 $0.06 CNC Turning 4 Axis SL-10, 1.75 , Includes Bar Feeder 5 2 10 100 47 4700 96 37.60 85% 113 31.96 74 1 8 74 1.0 1.0

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

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

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

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

$0.04 $0.15 $0.40 $0.00 $0.02 $0.02 $0.00 $0.04 6 Cavity Mold Box Size 120mm Dia x 23mm H 5 2 10 100 47 4700 96 37.60 85% 113 31.96 4 2 6 21 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: 5 of 9 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.

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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)

1A G Clutch Hub, Rivet Pin, M6 120301-B0602-60

2A G Clutch Hub, Washer, M5 120301-B0602-61

3A G Clutch Hub, Rivet Pin, M5 120301-B0602-62

$0.02

$0.01

$0.02

$0.00

$0.00

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

Total

$1.77 $2.05 $4.94 $0.01 $0.29 $0.20 $0.00 $0.50

$5.44

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: 6 of 9 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: 7 of 9 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)

G Clutch Hub Asm.

120301-B0602-59

Assembly 120301-B0602-59-01

G Clutch Hub, Isolator,Painted, Asm 120301-B0602-66

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! -

59 61.00 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

120301-B0602-66-01

120301-B0602-66-02

G Clutch Hub, Isolator, SBR

120301-B0602-66-03

120301-B0602-66-04

G Clutch Hub, Isolator, Outer

120301-B0602-66-05

120301-B0602-66-06

120301-B0602-66-07

G Clutch Hub, Isolator, Inner

120301-B0602-66-08

120301-B0602-66-09

120301-B0602-66-10

120301-B0602-66-11

G Clutch Hub, Face

120301-B0602-65-01

120301-B0602-65-02

120301-B0602-65-03

120301-B0602-65-04

120301-B0602-65-05

152 23.67 0.25

327 11.00 1.00

#DIV/0! #DIV/0!

720 5.00 0.50

1200 3.00 0.50

#DIV/0! #DIV/0! -

360 10.00 0.25

327 11.00 0.25

5143 0.70 0.25

#DIV/0! #DIV/0!

360 10.00 0.25

327 11.00 0.25

100 36.00 0.25

5143 0.70 0.25

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0!

152 23.67 0.25

360 10.00 0.25

327 11.00 0.25

150 24.00 1.00

1800 2.00 1.00

G Clutch Hub, Splined Hub

120301-B0602-64-01

120301-B0602-64-02

120301-B0602-64-03

K G Outer AC Clutch Hub

G cover, AC Clutch Hub

120301-B0602-67-01

#DIV/0! #DIV/0!

152 23.67 0.25

360 10.00 0.25

389 9.25 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

1029 3.50 1.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 9 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.

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

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! -

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

1A G Clutch Hub, Rivet Pin, M6 120301-B0602-60

2A G Clutch Hub, Washer, M5 120301-B0602-61

3A G Clutch Hub, Rivet Pin, M5 120301-B0602-62

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 9 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: 1 of 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-068 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 G Bracket, Stamped, AC 120301-B0602-68 0 #DIV/0! 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 Electroplate 120301-B0602-68-01 1 Electroplate T2/T3 Plate/Finish 

Mech., SSLC HC-Steel-1000S, Coil Plating/Coating Operator Plate/Finish, SMS, LMC 24000 1 1 5 0.000 $0.65 $40.84 $100.00 $500.00 $0.00 $0.00 $0.02 $0.02 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.02 $0.02 $0.00

4 Stamp 120301-B0602-68-03 1

G Bracket, Stamped T2/T3 Stamp/Form, 

SSLC HC-Steel-1000S, Coil Cut/Punch/Forming Operator-OEM

Stamp/Form, XSS 6000 0.25 1 1 0.016 $0.65 $135.07 $24.60 $24.60 $0.01 $0.01 $0.00 $0.02 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.02 $0.02 $0.01

5 0 #DIV/0! 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Cos

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)

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

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

Material

$0.01

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

Mark-up $0.05

T1 or OEM Total Manufacturing Cost: $0.01 $0.01 $0.02 $0.04 $0.00 $0.00 $0.00 $0.00 $0.00 $0.05

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 $0.01

Base Cost Impact to Vehicle: $0.01 $0.01 $0.02 $0.04 $0.00 $0.01 $0.00 $0.00 $0.01 $0.05 $0 $0

Packaging Cost: $0.00

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub3

1

Notes: 

a) Items 1,2, & 3 mus

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $0.05

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: 2 of 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-068 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 

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Cos

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% 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: 3 of 6 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)

G Bracket, Stamped, AC 120301-B0602-68

Electroplate 120301-B0602-68-01

Stamp 120301-B0602-68-03

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 $0.02 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00

Zinc Plating, Batched Processed

1 1 10 10 47 470 957 3.76 85% 1126 3.20 10 5 500 75 5.0 1.0

$0.01 $0.00 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00

Stamping Press 0-60 Ton 

1 1 10 10 47 470 957 3.76 85% 1126 3.20 0.6 1 1 0.6 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $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)

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

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

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

Total

$0.01 $0.02 $0.04 $0.00 $0.00 $0.00 $0.00 $0.00

$0.05

2

Notes: 

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

Thought on 0.5 Lines?

Also Parallel Processes

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 6 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: 5 of 6 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)

G Bracket, Stamped, AC 120301-B0602-68

Electroplate 120301-B0602-68-01

Stamp 120301-B0602-68-03

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! -

24000 0.15 1.00

6000 0.60 0.25

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

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

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! -

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 6 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: 1 of 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-069 Weekly Component Volume: Packaging Specification: Retrurnable 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 G Clutch Pully Asm 120301-B0602-69 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 120301-B0602-69-01 1 Assembly T2/T3 Mech. Assembly, 

SSLC

Not Applicable General Assembly Mech Assembly, LC, 

Base

240 2 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.32 $0.06 $0.38 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.42 $0.42 $0.00

12 120301-B0602-69-03 1 Machine T2/T3 CNC Turning, 

SSLC

Not Applicable CNC Operator CNC Machining, LC 100 1 1 1 0.000 $0.00 $36.98 $30.38 $30.38 $0.00 $0.37 $0.30 $0.67 0.30% 6.00% 4.00% 0.00% 10.30% $0.07 $0.74 $0.74 $0.00

13 120301-B0602-69-04 1

Paint Part Small T2/T3 Mech. Assembly, Not Applicable General Assembly Mech Assembly, LC, 310 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.03 $0.05 $0.08 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.09 $0.09 $0.00

Costs Broken Out In

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

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)

13 120301-B0602-69-04 1

SSLC

Not Applicable

Base

310 0.25 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.03 $0.05 $0.08 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.09 $0.09 $0.00

14 120301-B0602-69-05 1 Wash T2/T3 CNC Turning, 

SSLC

Not Applicable CNC Operator Washing Equipment, LC 360 0.25 1 1 0.000 $0.00 $36.98 $10.75 $10.75 $0.00 $0.03 $0.03 $0.06 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.06 $0.06 $0.00

15 120301-B0602-69-06 1 Machine T2/T3 CNC Turning, 

SSLC

Not Applicable CNC Operator CNC Machining, LC 113 1 2 1 0.000 $0.00 $36.98 $30.38 $60.76 $0.00 $0.33 $0.54 $0.87 0.30% 6.00% 4.00% 0.00% 10.30% $0.09 $0.96 $0.96 $0.00

120301-B0602-69-07 1 Heat Treat T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator T5-Al380, SMS 323 1.5 1 1 2.380 $0.01 $47.72 $10.17 $10.17 $0.02 $0.22 $0.03 $0.27 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.30 $0.30 $0.02

16 120301-B0602-69-08 1 Shake Out & Sand Removal T2/T3 CNC Turning, 

SSLC

Not Applicable Grinding/Polishing 

Operator

Sand Cast, Sand 

Removal, LS

240 1 1 1 0.000 $0.00 $42.14 $56.87 $56.87 $0.00 $0.18 $0.24 $0.41 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.46 $0.46 $0.00

17 120301-B0602-69-09 1

G Clutch Pulley,Cast

T2/T3 Sand Cast, SSLC Nodular Iron, 

Gr100/70/03, Cast

Mold/Cast/Sinter Operator Sand Cast Line, SMS 2769 1 1 1 2.380 $0.63 $41.48 $481.26 $481.26 $1.50 $0.01 $0.17 $1.69 5.00% 6.00% 4.00% 0.00% 15.00% $0.25 $1.94 $1.94 $1.50

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

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

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

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

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 G Clutch Pully, Friction Material 120301-B0602-70 1 s $0.00 $0.45 $0.00 $0.45 $0.45

2 G Clutch Pulley, Bearing 120301-B0602-71 1 s $0.00 $1.51 $0.00 $1.51 $1.51

3 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.

3 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$3.48

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

Mark-up $6.93

T1 or OEM Total Manufacturing Cost: $3.48 $1.49 $1.43 $6.40 $0.09 $0.27 $0.18 $0.00 $0.54 $6.93

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: $3.48 $1.49 $1.43 $6.40 $0.13 $0.72 $0.59 $0.17 $1.61 $8.01 $0 $0

3

1

Notes: 

a) Items 1,2, & 3 must a

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 6 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#: B0602 (B = Base, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, SEL, Mechanically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-B0602-069 Weekly Component Volume: Packaging Specification: Retrurnable 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

Electrically Versus Mechanically Driven Air Conditioning Compressor

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: $0.00

Net Cost Impact to Vehicle: $8.01

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

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

S. 020909)

Cost per Pallet /Rack

Total Number of Pallets/

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

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

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

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

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

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

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

File: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 6 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)

G Clutch Pully Asm 120301-B0602-69

120301-B0602-69-01

120301-B0602-69-03

120301-B0602-69-04

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

$0.32 $0.06 $0.38 $0.00 $0.02 $0.02 $0.00 $0.04 Low complexity, two workcells, gravity fed part transfer 5 2 10 100 47 4700 96 37.60 85% 113 31.96 29 2 1 15 1.0 1.0

$0.37 $0.30 $0.67 $0.00 $0.04 $0.03 $0.00 $0.07 "CNC Mach, Auto Sml Size and /or Low Complexity Pallet Size 300mm square 

550mm 5 2 10 100 47 4700 96 37.60 85% 113 31.96 36 1 1 36 1.0 1.0

$0.03 $0.05 $0.08 $0.00 $0.00 $0.00 $0.00 $0.01 5 2 10 100 47 4700 96 37.60 85% 113 31.96 12 1 1 12 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

120301-B0602-69-04

120301-B0602-69-05

120301-B0602-69-06

120301-B0602-69-07

120301-B0602-69-08

120301-B0602-69-09

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

G Clutch Pully, Friction Material 120301-B0602-70

G Clutch Pulley, Bearing 120301-B0602-71

$0.03 $0.05 $0.08 $0.00 $0.00 $0.00 $0.00 $0.01 5 2 10 100 47 4700 96 37.60 85% 113 31.96 12 1 1 12 1.0 1.0

$0.03 $0.03 $0.06 $0.00 $0.00 $0.00 $0.00 $0.01

Batch Type Washer, 5-10 minute cycle time Basket Size 15.75X18.5x25.5

5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 10 1.0 1.0

$0.33 $0.54 $0.87 $0.00 $0.05 $0.03 $0.00 $0.09 "CNC Mach, Auto Sml Size and /or Low Complexity Pallet Size 300mm square 

550mm 5 2 10 100 47 4700 96 37.60 85% 113 31.96 104 1 1 64 1.0 2.0

$0.22 $0.03 $0.27 $0.00 $0.02 $0.01 $0.00 $0.03 T5 Heat treat 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - - 2,420 27,000 1.0 1.0

$0.18 $0.24 $0.41 $0.00 $0.02 $0.02 $0.00 $0.04

Remove Mold Sand No Cores, then Trim Press

5 2 10 100 47 4700 96 37.60 85% 113 31.96 15 2 1 15 1.0 1.0

$0.01 $0.17 $1.69 $0.08 $0.10 $0.07 $0.00 $0.25 Sand Cast - 6 Cavities (3x2) of 2.38 lb per part 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1 3 6 8 1.0 1.0

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

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

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

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

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

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

$0.45

$1.51

$0.00

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

Total

$1.49 $1.43 $6.40 $0.09 $0.27 $0.18 $0.00 $0.54

$6.93

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: 4 of 6 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: 5 of 6 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)

G Clutch Pully Asm 120301-B0602-69

120301-B0602-69-01

120301-B0602-69-03

120301-B0602-69-04

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! -

240 15.00 2.00

100 36.00 1.00

120301-B0602-69-04 310 11.60 0.25

120301-B0602-69-05

120301-B0602-69-06

120301-B0602-69-07

120301-B0602-69-08

120301-B0602-69-09

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

G Clutch Pully, Friction Material 120301-B0602-70

G Clutch Pulley, Bearing 120301-B0602-71

310 11.60 0.25

360 10.00 0.25

113 32.00 1.00

323 11.16 1.50

240 15.00 1.00

2769 1.30 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! -

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 6 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
Indented Bill of Materials

G AC Systems

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

(Total)

G AC Pump Asm.

G AC Pump # 7.8659 lb # 7.8659 lb

Asm.

1 G Center Pump Asm. G Center Pump 1 # 4.9781 lb # 4.9781 lb

Asm.

2 G Rear Pump Housing, Asm. G Rear Pump 1 # 0.9262 lb # 0.9262 lb

Housing, Asm.

3 G Rear Pump Housing, G Rear Pump 1 # 0.8607 lb # 0.8607 lb

Machined Housing, 

Machined

4 G Rear Pump G Rear Pump 1 # 0.8607 lb # 0.8607 lb

Housing-Trimmed HousingTrimmed-1

5 G Rear Pump Housing-Cast G Rear 1 # 0.8607 lb # 0.8607 lb

Housing-Cast

6 G Front Cover-Raw Material G Rear 1 Aluminum - 380 # 0.8607 lb # 0.8607 lb

Housing-Raw 

Material

3 G Bearing, Needle, AC Pump G Bearing, 1 # 0.0551 lb # 0.0551 lb

Needle, AC 

Pump

3 G Dowel, Small, Rear Housing G Dowel, Small, 3 # 0.0016 lb # 0.0048 lb

Rear Housing

3 G Oing, Housing, AC Pump G Oing, Housing, 1 # 0.0056 lb # 0.0056 lb

AC Pump

2 G Spacer, Shaft, Large G Spacer, 1 # 0.0323 lb # 0.0323 lb

Shaft, Large

2 G Thrust Bearing, Shaft G Thrust 1 # 0.0145 lb # 0.0145 lb

Bearing, Shaft

2 G Spacer, Shaft, Small G Spacer, 1 # 0.0250 lb # 0.0250 lb

Shaft, Small

2 G Shaft and Swash Plate Asm. G Shaft and 1 # 0.8950 lb # 0.8950 lb

Swash Plate 

Asm.

3 G Shaft, AC Pump G Shaft, AC 1 # 0.5047 lb # 0.5047 lb

Pump

3 G Swash Plate, AC Pump G Swash Plate, 1 # 0.3903 lb # 0.3903 lb

AC Pump

Design Profit®
Tuesday, January 05, 2010 Page 

1 of5

Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

2 G Piston Asm. AC Compressor G Piston Asm. 5 # 0.1903 lb # 0.9515 lb

AC Compressor

3 G Piston, AC Compressor G Piston, AC 1 # 0.1863 lb # 0.9315 lb

Compressor

3 G Seal, Piston, AC Compressor G Seal, Piston, 2 # 0.0020 lb # 0.0200 lb

AC Compressor

2 G Bearing, Swash Plate to G Bearing, 10 # 0.0147 lb # 0.1470 lb

Piston Swash Plate to 

Piston

2 G Spacer, Shaft, Large G Spacer, 1 # 0.0323 lb # 0.0323 lb

Shaft, Large

2 G Thrust Bearing, Shaft G Thrust 1 # 0.0145 lb # 0.0145 lb

Bearing, Shaft

2 G Spacer, Shaft, Small G Spacer, 1 # 0.0250 lb # 0.0250 lb

Shaft, Small

2 G Gasket, Pump Housing G Gasket, Pump 1 # 0.0079 lb # 0.0079 lb

Housing

2 G Front Pump Housing, Asm G Front Pump 1 # 1.8469 lb # 1.8469 lb

Housing, Asm

3 G Front Pump Housing, G Front Pump 1 # 1.7750 lb # 1.7750 lb

Machined Housing, 

Machined

4 G Front Pump Housing, G Front Pump 1 # 1.7750 lb # 1.7750 lb

Trimmed Housing, 

Trimmed

5 G Front Pump Housing, Cast G Front Pump 1 Aluminum- # 1.7750 lb # 1.7750 lb

Housing, Raw Si8Cu3Fe

Material

6 G Front Pump Housing, Raw G Front Pump 1 Aluminum- # 1.7750 lb # 1.7750 lb

Material Housing, Raw Si8Cu3Fe

Material

3 G Bearing, Needle, AC Pump G Bearing, 1 # 0.0551 lb # 0.0551 lb

Needle, AC 

Pump

3 G Dowel, Large Front Housing G Dowel, Large 2 # 0.0056 lb # 0.0112 lb

Front Housing

3 G Oing, Housing, AC Pump G Oing, Housing, 1 # 0.0056 lb # 0.0056 lb

AC Pump

2 G Bolt, Front to Rear Housing G Bolt, Front to 3 # 0.0200 lb # 0.0600 lb

Rear Housing

1 G Steel Valve, AC Pump G Steel Valve, 1 # 0.0322 lb # 0.0322 lb

AC Pump

Design Profit®

Tuesday, January 05, 2010 Page 2 of 5
Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

2 G Steel Valve, AC Pump, G Steel Valve, 1 Steel Low # 0.0000 lb # 0.0000 lb

stamped AC Pump, Carbon Draw 

stamped Quality

1 G Valve Plate, Front Cover G Valve Plate, 1 # 0.3557 lb # 0.3557 lb

Front Cover

1 G Gasket, Front Cover G Gasket, Front 1 # 0.0265 lb # 0.0265 lb

Cover

1 G Front Cover Asm. G Front Cover 1 # 0.7678 lb # 0.7678 lb

Asm.

2 G Front Cover, Machined G Front Cover, 1 # 0.7465 lb # 0.7465 lb

Machined

3 G Front Cover-Trimmed G Front 1 Aluminum- # 0.7465 lb # 0.7465 lb

Cover-Trimmed Si8Cu3Fe

4 G Front Cover-Cast G Front 1 # 0.7465 lb # 0.7465 lb

Cover-Cast

5 G Front Cover-Raw Material G Front 1 Aluminum - 380 # 0.7465 lb # 0.7465 lb

Cover-Raw 

Material

2 G Seal, Front Cover G Seal, Front 1 # 0.0155 lb # 0.0155 lb

Cover

2 G Snap-ring, Seal Front Cover G Snap-ring, 1 # 0.0040 lb # 0.0040 lb

Seal Front Cover

2 G Dust Seal, Cloth, Front Cover G Dust Seal, 1 # 0.0018 lb # 0.0018 lb

Cloth, Front 

Cover

1 G Steel Valve, AC Pump G Steel Valve, 1 # 0.0322 lb # 0.0322 lb

AC Pump

1 G Valve Plate, Rear Cover G Valve Plate, 1 # 0.3693 lb # 0.3693 lb

Rear Cover

1 G Gasket, Rear Cover G Gasket, Rear 1 # 0.0250 lb # 0.0250 lb

Cover

1 G Rear Cover Asm. G Rear Cover 1 # 0.8741 lb # 0.8741 lb

Asm.

2 G Rear Cover, Machined G Rear Cover, 1 # 0.8418 lb # 0.8418 lb

Machined

3 G Rear Cover, Trimmed G Rear Cover, 1 Aluminum- # 0.8418 lb # 0.8418 lb

Trimmed Si8Cu3Fe

4 G Rear Cover, Cast G Rear Cover, 1 Aluminum- # 0.8418 lb # 0.8418 lb

Cast Si8Cu3Fe

5 G Rear Cover, Raw Material G Rear Cover, 1 Aluminum- # 0.8418 lb # 0.8418 lb

Raw Material Si8Cu3Fe

Design Profit®
Tuesday, January 05, 2010 Page 

3 of5

Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

2 G O-ring, Plug, Rear Cover G O-ring, Plug, 1 # 0.0001 lb # 0.0001 lb

Rear Cover

2 G Plug Asm. , Rear Cover G Plug Asm. , 1 # 0.0322 lb # 0.0322 lb

Rear Cover

1 G Bolt, Front Cover to Rear G Bolt, Front 5 # 0.0810 lb # 0.4050 lb

Cover to Rear

0 G Magnet Asm., AC Clutch G Magnet Asm., 1 ## 1.5650 lb ### 1.5650 lb

AC Clutch

0 G Snap-ring, AC Magnet G Snap-ring, AC 1 ## 0.0795 lb ### 0.0795 lb

Magnet

0 G Clutch Hub Asm. G Clutch Hub 1 ## 2.1870 lb ### 2.1870 lb

Asm.

1 G Cllutch Hub G Cllutch Hub 1 # 1.9100 lb # 1.9100 lb

1 G AC Clutch Material G AC Clutch 1 # 0.0058 lb # 0.0058 lb

Material

1 G Bearing, Clutch Hub G Bearing, 1 # 0.2712 lb # 0.2712 lb

Clutch Hub

0 G Snap-ring, AC Hub G Snap-ring, AC 1 ## 0.0768 lb ### 0.0768 lb

Hub

0 G Shim, Clutch Hub G Shim, Clutch 2 ## 0.0008 lb ### 0.0016 lb

Hub

0 G Outer A G Outer AC Clutch Hub C Clutch Hub G Outer A G Outer AC 1 ## 0.9800 lb 0.9800 lb ### 0.9800 lb 0.9800 lb

Clutch Hub

0 G Bolt, Outer AC Hub G Bolt, Outer AC 1 ## 0.0130 lb ### 0.0130 lb

Hub

0 G cover, AC Clutch Hub G cover, AC 1 ## 0.1250 lb ### 0.1250 lb

Clutch Hub

0 G Bolt, AC Clutch Hub Cover G Bolt, AC 3 ## 0.0042 lb ### 0.0126 lb

Clutch Hub 

Cover

0 G Bracket, Stamped, AC G Bracket, 1 ## 0.0060 lb ### 0.0060 lb

electrical Stamped, AC 

electrical

0 G Bolt, Bracket, AC Electrical G Bolt, Bracket, 1 ## 0.0055 lb ### 0.0055 lb

AC Electrical

Design Profit®

Tuesday, January 05, 2010 Page 4 of 5
Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

Assembly Totals Report Totals Preassembled Totals

Analyzed Subs: # Piece Cost (Total): Analyzed Subs:

Unanalyzed Subs: # Unanalyzed Subs:

Weight (Total): 12.9179 lb

Parts: # Parts:

Fasteners: # Fasteners:

Parts+Unanalyzed: # Parts+Unanalyzed:

Design Profit®

Tuesday, January 05, 2010 Page 5 of 5
Copyright 2005© Munro & Associates, Inc.
0.8607 lb

0.9515 lb

1.7750 lb







Indented Bill of Materials

G AC Systems

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

(Total)

G AC Pump Asm. G AC Pump 7.8659 lb 7.8659 lb Asm.

1 G Center Pump Asm. G Center 1 # 4.9781 lb # 4.9781 lb

Pump Asm.

2 G Rear Pump Housing, Asm. G Rear Pump 1 # 0.9262 lb # 0.9262 lb

Housing, Asm.

3 G Rear Pump Housing, Wash G Rear Pump 1 Aluminum- # 0.8607 lb # 0.8607 lb

Housing, Wash Si8Cu3Fe

4 G Rear Pump Housing, G Rear Pump 1 # 0.8607 lb # 0.8607 lb

Machined Housing, 

Machined

5 G Rear Pump G Rear Pump 1 # 0.8607 lb # 0.8607 lb

Housing-Trimmed HousingTrimmed-1

6 G Rear Pump Housing-Cast G Rear 1 Aluminum- # 0.8607 lb # 0.8607 lb

Housing-Cast Si8Cu3Fe

7 G Rear Pump Housing, Alum G Rear Pump 1 ### 0.8607 lb ## 0.8607 lb

Matl Housing, Alum 

Matl

3 G Bearing, Needle, AC Pump G Bearing, 1 # 0.0551 lb # 0.0551 lb

Needle, AC 

Pump

3 G Dowel, Small, Rear Housing G Dowel, Small, 3 Commodity # 0.0016 lb # 0.0048 lb

Rear Housing Pricing

3 G O-Ring, Housing, AC Pump G O-Ring, 1 # 0.0056 lb # 0.0056 lb

Housing, AC 

Pump

4 G O-Ring, Housing, AC Pump, G O-Ring, 1 SBR # 0.0056 lb # 0.0056 lb

SBR Mtl Housing, AC 

Pump, SBR Mtl

2 G Spacer, Shaft, Large G Spacer, 1 # 0.0323 lb # 0.0323 lb

Shaft, Large

2 G Thrust Bearing, Shaft G Thrust 1 # 0.0145 lb # 0.0145 lb

Bearing, Shaft

2 G Spacer, Shaft, Small G Spacer, 1 # 0.0250 lb # 0.0250 lb

Shaft, Small

Design Profit ®

Page 1 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

G Shaft and Swash Plate G Shaft and 1 0.8950 lb 0.8950 lb

Asm. Swash Plate 

Asm.

3 G Shaft, AC Pump G Shaft, AC 1 # 0.5047 lb # 0.5047 lb

Pump

4 G Shaft, AC Pump, Wash G Shaft, AC 1 # 0.5047 lb # 0.5047 lb

Pump, Wash

5 G Shaft, AC Pump, Trimmed G Shaft, AC 1 # 0.5047 lb # 0.5047 lb

Pump, 

Trimmed

3 G Swash Plate, AC Pump G Swash Plate, 1 # 0.3903 lb # 0.3903 lb

AC Pump

2 G Piston Asm. AC G Piston Asm. 5 # 0.1903 lb # 0.9515 lb

Compressor AC

Compressor

3 G Piston, AC Compressor, G Piston, AC 1 # 0.1863 lb # 0.9315 lb

Washed Compressor, 

Washed

4 G Piston, AC Compressor, G Piston, AC 1 Aluminum- # 0.1863 lb # 0.9315 lb

Machine Compressor, Si8Cu3Fe

Machine

5 G Piston, A G Piston, AC Compressor, C Compressor, G Piston, A G Piston, AC 1 # 0.1863 lb 0.1863 lb # 0.9315 lb 0.9315 lb

Trimmed Compressor, 

Trimmed

6 G Piston, AC Compressor, G Piston, AC 1 A380 # 0.1863 lb # 0.9315 lb

Cast Compressor, 

Cast

7 G Piston, AC Compressor, G Piston, AC 1 A380 ### 0.1863 lb ## 0.9315 lb

Alum Mtl Compressor, 

Alum Mtl

3 G Seal, Piston, AC G Seal, Piston, 2 # 0.0020 lb # 0.0200 lb

Compressor AC

Compressor

4 G Seal, Piston, AC G Seal, Piston, 1 Teflon # 0.0020 lb # 0.0200 lb

Compressor, Teflon Mtl AC 

Compressor, 

Teflon Mtl

2 G Bearing, Swash Plate to G Bearing, # # 0.0147 lb # 0.1470 lb

Piston Swash Plate to 

Piston

2 G Spacer, Shaft, Large G Spacer, 1 # 0.0323 lb # 0.0323 lb

Shaft, Large

Design Profit ®
Page 

2 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

G Thrust Bearing, Shaft G Thrust 1 0.0145 lb 0.0145 lb

Bearing, Shaft

2 G Spacer, Shaft, Small G Spacer, 1 # 0.0250 lb # 0.0250 lb

Shaft, Small

2 G Gasket, Pump Housing G Gasket, 1 # 0.0079 lb # 0.0079 lb

Pump Housing

3 G Gasket, Pump Housing, G Gasket, 1 OVERMOLDED # 0.0000 lb # 0.0000 lb

Material Pump Housing, STEEL

Material

2 G Front Pump Housing, Asm G Front Pump 1 # 1.8469 lb # 1.8469 lb

Housing, Asm

3 G Front Pump Housing, Wash G Front Pump 1 Aluminum- # 1.7750 lb # 1.7750 lb

Housing, Wash Si8Cu3Fe

4 G Front Pump Housing, G Front Pump 1 # 1.7750 lb # 1.7750 lb

Machined Housing, 

Machined

5 G Front Pump Housing, G Front Pump 1 # 1.7750 lb # 1.7750 lb

Trimmed Housing, 

Trimmed

6 G Front Pump Housing, Cast G Front Pump 1 Aluminum- # 1.7750 lb # 1.7750 lb

Housing, Raw Si8Cu3Fe

Material

7 G Front Pump Housing, Alum G Front Pump 1 ### 1.7750 lb ## 1.7750 lb

Mtl Housing, Alum 

Mtl

3 G Bearing, Needle, AC Pump G Bearing, 1 # 0.0551 lb # 0.0551 lb

Needle, AC 

Pump

3 G Dowel, Large Front Housing G Dowel, Large 2 Commodity # 0.0056 lb # 0.0112 lb

Front Housing Pricing

3 G O-Ring, Housing, AC Pump G O-Ring, 1 # 0.0056 lb # 0.0056 lb

Housing, AC 

Pump

4 G O-Ring, Housing, AC Pump, G O-Ring, 1 SBR # 0.0056 lb # 0.0056 lb

SBR Mtl Housing, AC 

Pump, SBR Mtl

2 G Bolt, Front to Rear Housing G Bolt, Front to 3 Commodity # 0.0200 lb # 0.0600 lb

Rear Housing Pricing

1 G Steel Valve, AC Pump G Steel Valve, 1 Steel - 1040 # 0.0322 lb # 0.0322 lb

AC Pump

Design Profit ®

Page 3 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

G Steel Valve, AC Pump, G Steel Valve, 1 0.0322 lb 0.0322 lb

Deburred AC Pump, 

Deburr-1

3 G Steel Valve, AC Pump, G Steel Valve, 1 Steel - 1040 # 0.0322 lb # 0.0322 lb

Stamped AC Pump, 

stamped

4 G Steel Valve, AC Pump, G Steel Valve, 1 Steel - 1040 # 0.0322 lb # 0.0322 lb

Material AC Pump, 

Material

1 G Valve Plate, Front Cover G Valve Plate, 1 # 0.3490 lb # 0.3490 lb

Front Cover

2 G Valve Plate, Base, Front G Valve Plate, 1 # 0.2950 lb # 0.2950 lb

Base, Front

3 G Valve Plate, Base, Wash, , G Valve Plate, 1 # 0.2950 lb # 0.2950 lb

Front Base, Wash, 

Front

4 G Valve Plate, Trimmed, Front G Valve Plate, 1 # 0.2950 lb # 0.2950 lb

Trimmed, 

Front

5 G Steel Valve, Valve Plate G Steel Valve, 1 Steel - 1018 # 0.2950 lb # 0.2950 lb

Base, Front Valve Plate 

Base, Front

2 G Valve Plate, Valve G Valve Plate, 1 Steel - 1040 # 0.0050 lb # 0.0050 lb

Valve

3 G Valve Plate, Valve G Valve Plate, 1 Steel - 1040 # 0.0050 lb # 0.0050 lb

Valve, 

Deburred

4 G Valve Plate, Valve G Valve Plate, 1 Steel - 1040 # 0.0050 lb # 0.0050 lb

Valve, 

Stamped

5 G Valve Plate, Valve G Valve Plate, 1 Steel - 1040 # 0.0050 lb # 0.0050 lb

Valve

2 G Valve Plate, Top G Valve Plate, 1 # 0.0450 lb # 0.0450 lb

Top

3 G Valve Plate, Top, Deburred G Valve Plate, 1 Steel - 1018 # 0.0450 lb # 0.0450 lb

Top, Deburred

4 G Valve Plate, Top, Stamped G Valve Plate, 1 # 0.0450 lb # 0.0450 lb

Top, Stamped

5 G Steel Valve, Top G Steel Valve, 1 Steel - 1018 # 0.0450 lb # 0.0450 lb

Top

2 G Valve Plate, Pin G Valve Plate, 4 Commodity # 0.0010 lb # 0.0040 lb

Pin Pricing

Design Profit ®

Page 4 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

G Gasket, Front Cover G Gasket, # 0.0265 lb 0.0265 lb

Front Cover

2 G Gasket, Front Cover, Material G Gasket, Front 1 OVERMOLDED # 0.0000 lb # 0.0000 lb

Cover, Material STEEL

1 G Front Cover Asm. G Front Cover 1 # 0.7678 lb # 0.7678 lb

Asm.

2 G Front Cover, Wash G Front Cover, 1 Aluminum- # 0.7465 lb # 0.7465 lb

Wash Si8Cu3Fe

3 G Front Cover, Machined G Front Cover, 1 # 0.7465 lb # 0.7465 lb

Machined

4 G Front Cover-Trimmed G Front 1 Aluminum- # 0.7465 lb # 0.7465 lb

Cover- Si8Cu3Fe

Trimmed

5 G Front Cover Asm, Casting G Front Cover 1 # 0.7465 lb # 0.7465 lb

Asm, Casting

6 G Front Cover-Alum Mtl G Front 1 A380 # 0.7465 lb # 0.7465 lb

Cover-Alum Mtl

2 G Seal, Front Cover G Seal, Front 1 # 0.0155 lb # 0.0155 lb

Cover

2 G Snap-ring, Seal Front Cover G Snap-ring, 1 # 0.0040 lb # 0.0040 lb

Seal Front 

Cover

2 G Dust Seal, Cloth, Front Cover G Dust Seal, 1 # 0.0018 lb # 0.0018 lb

Cloth, Front 

Cover

1 G Steel Valve, AC Pump G Steel Valve, 1 Steel - 1040 # 0.0322 lb # 0.0322 lb

AC Pump

2 G Steel Valve, AC Pump, G Steel Valve, 1 # 0.0322 lb # 0.0322 lb

Deburred AC Pump, 

Deburr-1

3 G Steel Valve, AC Pump, G Steel Valve, 1 Steel - 1040 # 0.0322 lb # 0.0322 lb

Stamped AC Pump, 

stamped

4 G Steel Valve, AC Pump, G Steel Valve, 1 Steel - 1040 # 0.0322 lb # 0.0322 lb

Material AC Pump, 

Material

1 G Valve Plate, Rear Cover G Valve Plate, 1 # 0.3490 lb # 0.3490 lb

Rear Cover

2 G Valve Plate, Base, Rear G Valve Plate, 1 # 0.2950 lb # 0.2950 lb

Base, Rear

Design Profit ®
Page 

5 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

3 G Valve Plate, Base, Wash, G Valve Plate, 1 # 0.2950 lb 0.2950 lb

Rear Base, Wash, 

Rear

4 G Valve Plate, Base, Trimmed G Valve Plate, 1 # 0.2950 lb # 0.2950 lb

Rear Base, 

Trimmed, Rear

5 G Steel Valve, Valve Plate G Steel Valve, 1 Steel - 1018 # 0.2950 lb # 0.2950 lb

Base, Rear Valve Plate 

Base, Rear

2 G Valve Plate, Valve G Valve Plate, 1 Steel - 1040 # 0.0050 lb # 0.0050 lb

Valve

3 G Valve Plate, Valve G Valve Plate, 1 Steel - 1040 # 0.0050 lb # 0.0050 lb

Valve, 

Deburred

4 G Valve Plate, Valve G Valve Plate, 1 Steel - 1040 # 0.0050 lb # 0.0050 lb

Valve, 

Stamped

5 G Valve Plate, Valve G Valve Plate, 1 Steel - 1040 # 0.0050 lb # 0.0050 lb

Valve

2 G Valve Plate, Top G Valve Plate, 1 # 0.0450 lb # 0.0450 lb

Top

3 G Valve Plate, Top, Deburred G Valve Plate, Top, Deburred G Valve Plate, G Valve Plate, 1 Steel - 1018 Steel - 1018 # 0.0450 lb 0.0450 lb # 0.0450 lb 0.0450 lb

Top, Deburred

4 G Valve Plate, Top, Stamped G Valve Plate, 1 # 0.0450 lb # 0.0450 lb

Top, Stamped

5 G Steel Valve, Top G Steel Valve, 1 Steel - 1018 # 0.0450 lb # 0.0450 lb

Top

2 G Valve Plate, Pin G Valve Plate, 4 Commodity # 0.0010 lb # 0.0040 lb

Pin Pricing

1 G Gasket, Rear Cover G Gasket, Rear 1 # 0.0250 lb # 0.0250 lb

Cover

2 G Gasket, Rear Cover, Material G Gasket, Rear 1 OVERMOLDED # 0.0000 lb # 0.0000 lb

Cover, Material STEEL

1 G Rear Cover Asm G Rear Cover 1 # 0.8741 lb # 0.8741 lb

Asm

2 G Rear Cover, Washed G Rear Cover, 1 # 0.8418 lb # 0.8418 lb

Washed

3 G Rear Cover, Mach G Rear Cover, 1 # 0.8418 lb # 0.8418 lb

Mach

4 G Rear Cover, Trimmed G Rear Cover, 1 Aluminum- # 0.8418 lb # 0.8418 lb

Trimmed Si8Cu3Fe

Design Profit ®

Page 6 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

G Rear Cover, Casting G Rear Cover, 1 0.8418 lb 0.8418 lb

Casting

6 G Rear Cover, Alum Mtl G Rear Cover, 1 Aluminum A380 # 0.8418 lb # 0.8418 lb

Alum Mtl

2 G O-ring, Plug, Rear Cover G O-ring, Plug, 1 # 0.0001 lb # 0.0001 lb

Rear Cover

2 G Plug Asm. , Rear Cover G Plug Asm. , 1 # 0.0322 lb # 0.0322 lb

Rear Cover

1 G Bolt, Front Cover to Rear G Bolt, Front 5 Commodity # 0.0810 lb # 0.4050 lb

Cover to Rear Pricing

0 G Magnet Asm., AC Clutch G Magnet 1 # 1.5650 lb # 1.5650 lb

Asm., AC 

Clutch

0 G Snap-ring, AC Magnet G Snap-ring, 1 # 0.0124 lb # 0.0124 lb

AC Magnet

0 G Clutch Pully Asm G Clutch Pully 1 # 2.1870 lb # 2.1870 lb

Asm

1 G Clutch Pulley G Clutch 1 # 1.9100 lb # 1.9100 lb

Pulley

2 G Clutch Pulley, Machined G Clutch 1 # 1.9100 lb # 1.9100 lb

Final Pulley, 

Machined Final

3 G Clutch Pulley, Paint G Clutch 1 # 1.9100 lb # 1.9100 lb

Pulley, Paint

4 G Clutch Pulley, Machined G Clutch 1 # 1.9100 lb # 1.9100 lb

Pulley, 

Machined

1 G Clutch Pully, Friction Material G Clutch Pully, 1 # 0.0058 lb # 0.0058 lb

Friction Material

1 G Clutch Pulley, Bearing G Clutch 1 # 0.2712 lb # 0.2712 lb

Pulley, Bearing

0 G Snap-ring, AC Hub G Snap-ring, 1 # 0.0121 lb # 0.0121 lb

AC Hub

0 G Shim, Clutch Hub G Shim, Clutch 2 Commodity # 0.0008 lb # 0.0016 lb

Hub Pricing

0 G Clutch Hub Asm G Clutch Hub 1 # 0.9800 lb # 0.9800 lb

Asm

1 G Clutch Hub, Rivet Pin, M5 G Clutch Hub, 3 Commodity # 0.0045 lb # 0.0135 lb

Rivet Pin, M5 Pricing

1 G Clutch Hub, Isolator, G Clutch Hub, 1 # 0.3400 lb # 0.3400 lb

Painted Asm Isolator, 

Painted Asm

Design Profit ®
Page 

7 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

G Clutch Hub, Isolator, Insert G Clutch Hub, 1 0.3400 lb 0.3400 lb

Molded Asm Isolator, Insert 

Molded Asm

3 G Clutch Hub, Isolator, Inner, G Clutch Hub, 1 Steel - 1018 # 0.1570 lb # 0.1570 lb

Washed Isolator, Inner, 

Washed

4 G Clutch Hub, Isolator, Inner, G Clutch Hub, 1 Steel - 1018 # 0.1570 lb # 0.1570 lb

Deburred Isolator, Inner, 

Deburred

5 G Clutch Hub, Isolator, Inner, G Clutch Hub, 1 Steel - 1018 # 0.1570 lb # 0.1570 lb

Machined Isolator, Inner, 

Machined

6 G Clutch Hub, Isolator, Inner, G Clutch Hub, 1 Steel - 1018 # 0.1570 lb # 0.1570 lb

Stamped Isolator, Inner, 

Stamped

7 G Clutch Hub, Isolator, Inner, G Clutch Hub, 1 Steel - 1018 ### 0.1570 lb ## 0.1570 lb

Stell Isolator, Inner, 

Steel

3 G Clutch Hub, Isolator, Outer, G Clutch Hub, 1 Steel - 1018 # 0.1156 lb # 0.1156 lb

Washed Isolator, Outer, 

Washed

4 G Clutch Hub, Isolator, Outer, G Clutch Hub, Isolator, Outer, G Clutch Hub, G Clutch Hub, 1 Steel - 1018 Steel - 1018 # 0.1156 lb 0.1156 lb # 0.1156 lb 0.1156 lb

Deburred Isolator, Outer, 

Deburred

5 G Clutch Hub, Isolator, Outer, G Clutch Hub, 1 Steel - 1018 # 0.1156 lb # 0.1156 lb

Stamped Isolator, Outer, 

Stamped

6 G Clutch Hub, Isolator, Outer, G Clutch Hub, 1 Steel - 1018 # 0.1156 lb # 0.1156 lb

Steel Isolator, Outer, 

Steel

3 G Clutch Hub, Isolator, SBR G Clutch Hub, 1 SBR # 0.0674 lb # 0.0674 lb

Isolator, SBR

1 G Clutch Hub, Washer, M5 G Clutch Hub, 3 Commodity # 0.0006 lb # 0.0018 lb

Washer, M5 Pricing

1 G Clutch Hub, Face G Clutch Hub, 1 Steel - 1018 # 0.5067 lb # 0.5067 lb

Face

2 G Clutch Hub, Face, Washed G Clutch Hub, 1 Steel - 1018 # 0.5067 lb # 0.5067 lb

Face, Washed

3 G Clutch Hub, Face, Deburred G Clutch Hub, 1 Steel - 1018 # 0.5067 lb # 0.5067 lb

Face, 

Deburred

Design Profit ®

Page 8 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

G Clutch Hub, Face, G Clutch Hub, Steel - 1018 0.5067 lb 0.5067 lb

Machined Face, 

Deburred-1

5 G Clutch Hub, Face, Stamped G Clutch Hub, 1 Steel - 1018 # 0.5067 lb # 0.5067 lb

Face, Stamped

6 G Clutch Hub, Face, Steel G Clutch Hub, 1 Steel - 1018 # 0.5067 lb # 0.5067 lb

Face, Steel

1 G Clutch Hub, Splined Hub, G Clutch Hub, 1 Steel - 1018 # 0.1015 lb # 0.1015 lb

Painted Splined Hub, 

Painted

2 G Clutch Hub, Splined Hub, G Clutch Hub, 1 Steel 1018 # 0.1015 lb # 0.1015 lb

Washed Splined Hub, 

Washed

3 G Clutch Hub, Splined Hub, G Clutch Hub, 1 Steel 1018 # 0.1015 lb # 0.1015 lb

Broached Splined Hub, 

Broached

4 G Clutch Hub, Splined Hub, G Clutch Hub, 1 Steel - 1018 # 0.1015 lb # 0.1015 lb

CNC Turned Splined Hub, 

CNC Turned

5 G Clutch Hub, Center Hub, G Clutch Hub, 1 Steel - 1018 # 0.1015 lb # 0.1015 lb

Splined, Steel Bar Center Hub, 

Splined, Steel 

Bar

1 G Clutch Hub, Rivet Pin, M6 G Clutch Hub, 3 Commodity # 0.0055 lb # 0.0165 lb

Rivet Pin, M6 Pricing

0 G Bolt, Clutch Hub G Bolt, Clutch 1 Commodity # 0.0130 lb # 0.0130 lb

Hub Pricing

0 G Clutch Hub, Cover, Molded G Clutch Hub, 1 # 0.1250 lb # 0.1250 lb

Cover, Molded

1 G Clutch Hub, Cover, Material G Clutch Hub, 1 PBT GF20 # 0.0000 lb # 0.0000 lb

Cover, Material

0 G Bolt, AC Clutch Hub Cover G Bolt, AC 3 Commodity # 0.0042 lb # 0.0126 lb

Clutch Hub Pricing

Cover

0 G Bracket, AC Electrical, Zinc G Bracket, AC 1 Steel - 1008 # 0.0060 lb # 0.0060 lb

Plated Electrical, Zinc 

Plated

1 G Bracket, AC Electrical, G Bracket, AC 1 Steel - 1008 # 0.0060 lb # 0.0060 lb

Washed Electrical, 

Washed

2 G Bracket, AC Electrical, G Bracket, AC 1 Steel - 1008 # 0.0060 lb # 0.0060 lb

Stamped Electrical, 

Stamped

Design Profit ®
Page 

9 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

3 G Bracket, AC Electrical, Steel G Bracket, AC 1 Steel - 1008 # 0.0060 lb 0.0060 lb

Electrical, Steel

0 G Bolt, Bracket, AC Electrical G Bolt, Bracket, 1 Commodity # 0.0055 lb # 0.0055 lb

AC Electrical Pricing

Assembly Totals Report Totals Preassembled Totals

Analyzed Subs: # Piece Cost (Total): # Analyzed Subs:

Unanalyzed Subs:# Unanalyzed Subs:

Weight (Total): 12.7861 lb

Parts: # Parts:

Fasteners: # Fasteners:

Parts+Unanalyzed:# Parts+Unanalyzed:

Design Profit ®

Page # of #
Copyright 2005© Munro & Associates, Inc.
0.8607 lb

0.9315 lb

1.7750 lb





0.2950 lb

0.8418 lb

0.1570 lb

0.5067 lb



Indented Bill of Materials

G AC Systems

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

(Total)

G AC Systems G AC 12.7784 lb 12.7784 lb SystemsInstallation

1 G AC Pump Asm. G AC Pump 1 # 7.8659 lb # 7.8659 lb

Asm.

2 G Center Pump Asm. G Center 1 ## 4.9781 lb # 4.9781 lb

Pump Asm.

3 G Rear Pump Housing, Asm. G Rear Pump 1 # 0.9262 lb # 0.9262 lb

Housing, 

Asm.

4 G Rear Pump Housing, Wash G Rear Pump 1 Aluminum- # 0.8607 lb # 0.8607 lb

Housing, Si8Cu3Fe

Wash

5 G Rear Pump Housing, G Rear Pump 1 # 0.8607 lb # 0.8607 lb

Machined Housing, 

Machined

6 G Rear Pump G Rear Pump 1 # 0.8607 lb # 0.8607 lb

Housing-Trimmed HousingTrimmed-1

7 G Rear Pump Housing-Cast G Rear 1 Aluminum- ## 0.8607 lb ## 0.8607 lb

Housing-Cast Si8Cu3Fe

8 G Rear Pump Housing, Alum G Rear Pump 1 A380 # 0.8607 lb # 0.8607 lb

Matl Housing, Alum 

Matl

4 G Bearing, Needle, AC Pump G Bearing, 1 Commodity # 0.0551 lb # 0.0551 lb

Needle, AC Pricing

Pump

4 G Dowel, Small, Rear Housing G Dowel, 3 Commodity # 0.0016 lb # 0.0048 lb

Small, Rear Pricing

Housing

4 G O-Ring, Housing, AC Pump G O-Ring, 1 Commodity # 0.0056 lb # 0.0056 lb

Housing, AC Pricing

Pump

4 Small- Self-Adhesive, Printed, Small- 1 # 0.0000 lb # 0.0000 lb

Label Self-Adhesive, 

Printed, Label

3 G Spacer, Shaft, Large G Spacer, 1 Commodity # 0.0323 lb # 0.0323 lb

Shaft, Large Pricing

Design Profit ®

Page 1 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

3 G Thrust Bearing, Shaft G Thrust Commodity 0.0145 lb 0.0145 lb

Bearing, Shaft Pricing

3 G Spacer, Shaft, Small G Spacer, 1 Commodity # 0.0250 lb # 0.0250 lb

Shaft, Small Pricing

3 G Shaft and Swash Plate G Shaft and 1 # 0.8950 lb # 0.8950 lb

Asm. Swash Plate 

Asm.

4 G Shaft, AC Pump G Shaft, AC 1 # 0.5047 lb # 0.5047 lb

Pump

5 G Shaft, AC Pump, Wash G Shaft, AC 1 # 0.5047 lb # 0.5047 lb

Pump, Wash

6 G Shaft, AC Pump, Trimmed G Shaft, AC 1 # 0.5047 lb # 0.5047 lb

Pump, 

Trimmed

7 G Shaft, AC Pump, Bar Stock G Shaft, AC 1 Steel - 1040 ## 0.0000 lb ## 0.0000 lb

Pump, Bar 

Stock

4 G Swash Plate, AC Pump G Swash 1 # 0.3903 lb # 0.3903 lb

Plate, AC 

Pump

3 G Piston Asm. AC G Piston Asm. 5 # 0.1903 lb # 0.9515 lb

Compressor AC

Compressor

4 G Piston, AC Compressor, G Piston, AC 1 # 0.1863 lb # 0.9315 lb

Washed Compressor, 

Washed

5 G Piston, AC Compressor, G Piston, AC 1 Aluminum- # 0.1863 lb # 0.9315 lb

Machine Compressor, Si8Cu3Fe

Machine

6 G Piston, AC Compressor, G Piston, AC 1 # 0.1863 lb # 0.9315 lb

Trimmed Compressor, 

Trimmed

7 G Piston, AC Compressor, G Piston, AC 1 A380 ## 0.1863 lb ## 0.9315 lb

Cast Compressor, 

Cast

8 G Piston, AC Compressor, G Piston, AC 1 A380 # 0.1863 lb # 0.9315 lb

Alum Mtl Compressor, 

Alum Mtl

4 G Seal, Piston, AC G Seal, 2 # 0.0020 lb # 0.0200 lb

Compressor Piston, AC 

Compressor

Design Profit ®

Page 2 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

G Seal, Piston, AC G Seal, Piston, Teflon # 0.0020 lb 0.0200 lb

Compressor, Teflon Mtl AC 

Compressor, 

Teflon Mtl

3 G Bearing, Swash Plate to G Bearing, # Commodity # 0.0147 lb # 0.1470 lb

Piston Swash Plate Pricing

to Piston

3 G Spacer, Shaft, Large G Spacer, 1 Commodity # 0.0323 lb # 0.0323 lb

Shaft, Large Pricing

3 G Thrust Bearing, Shaft G Thrust 1 Commodity # 0.0145 lb # 0.0145 lb

Bearing, Shaft Pricing

3 G Spacer, Shaft, Small G Spacer, 1 Commodity # 0.0250 lb # 0.0250 lb

Shaft, Small Pricing

3 G Gasket, Pump Housing G Gasket, 1 # 0.0079 lb # 0.0079 lb

Pump 

Housing

4 G Gasket, Pump Housing, G Gasket, 1 OVERMOLDE # 0.0000 lb # 0.0000 lb

Material Pump Housing, D STEEL

Material

3 G Front Pump Housing, Asm G Front Pump 1 # 1.8469 lb # 1.8469 lb

Housing, Asm

4 G Front Pump Housing, G Front Pump Housing, G Front Pump G Front Pump 1 Aluminum- uminum- # 1.7750 lb 1.7750 lb # 1.7750 lb 1.7750 lb

Wash Housing, Si8Cu3Fe

Wash

5 G Front Pump Housing, G Front Pump 1 # 1.7750 lb # 1.7750 lb

Machined Housing, 

Machined

6 G Front Pump Housing, G Front Pump 1 # 1.7750 lb # 1.7750 lb

Trimmed Housing, 

Trimmed

7 G Front Pump Housing, Cast G Front Pump 1 Aluminum- ## 1.7750 lb ## 1.7750 lb

Housing, Raw Si8Cu3Fe

Material

8 G Front Pump Housing, Alum G Front Pump 1 # 1.7750 lb # 1.7750 lb

Mtl Housing, Alum 

Mtl

4 G Bearing, Needle, AC Pump G Bearing, 1 Commodity # 0.0551 lb # 0.0551 lb

Needle, AC Pricing

Pump

4 G Dowel, Large Front Housing G Dowel, 2 Commodity # 0.0056 lb # 0.0112 lb

Large Front Pricing

Housing

Design Profit ®
Page 

3 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

G O-Ring, Housing, AC Pump G O-Ring, 1 Commodity # 0.0056 lb 0.0056 lb

Housing, AC Pricing

Pump

4 Small- Self-Adhesive, Printed, Small- 1 # 0.0000 lb # 0.0000 lb

Label Self-Adhesive, 

Printed, Label

3 G Bolt, Front to Rear Housing G Bolt, Front to 3 Commodity # 0.0200 lb # 0.0600 lb

Rear Housing Pricing

2 G Steel Valve, AC Pump G Steel Valve, 1 Steel - 1040 ## 0.0322 lb # 0.0322 lb

AC Pump

3 G Steel Valve, AC Pump, G Steel Valve, 1 # 0.0322 lb # 0.0322 lb

Deburred AC Pump, 

Deburr-1

4 G Steel Valve, AC Pump, G Steel Valve, 1 Steel - 1040 # 0.0322 lb # 0.0322 lb

Stamped AC Pump, 

stamped

5 G Steel Valve, AC Pump, G Steel Valve, 1 Steel - 1040 # 0.0322 lb # 0.0322 lb

Material AC Pump, 

Material

2 G Valve Plate, Front Cover G Valve Plate, 1 ## 0.3490 lb # 0.3490 lb

Front Cover

3 G Valve Plate, Base, Front G Valve Plate, Base, Front G Valve Plate, G Valve Plate, 1 # 0.2950 lb 0.2950 lb # 0.2950 lb 0.2950 lb

Base, Front

4 G Valve Plate, Base, Wash, , G Valve Plate, 1 # 0.2950 lb # 0.2950 lb

Front Base, Wash, 

Front

5 G Valve Plate, Trimmed, G Valve Plate, 1 # 0.2950 lb # 0.2950 lb

Front Trimmed, 

Front

6 G Steel Valve, Valve Plate G Steel Valve, 1 Steel - 1018 # 0.2950 lb # 0.2950 lb

Base, Front Valve Plate 

Base, Front

3 G Valve Plate, Valve G Valve Plate, 1 Steel - 1040 # 0.0050 lb # 0.0050 lb

Valve

4 G Valve Plate, Valve G Valve Plate, 1 Steel - 1040 # 0.0050 lb # 0.0050 lb

Valve, 

Deburred

5 G Valve Plate, Valve G Valve Plate, 1 Steel - 1040 # 0.0050 lb # 0.0050 lb

Valve, 

Stamped

6 G Valve Plate, Valve G Valve Plate, 1 Steel - 1040 # 0.0050 lb # 0.0050 lb

Valve

Design Profit ®
Page 

4 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

3 G Valve Plate, Top G Valve Plate, 0.0450 lb 0.0450 lb

Top

4 G Valve Plate, Top, Deburred G Valve Plate, 1 Steel - 1018 # 0.0450 lb # 0.0450 lb

Top, Deburred

5 G Valve Plate, Top, Stamped G Valve Plate, 1 # 0.0450 lb # 0.0450 lb

Top, Stamped

6 G Steel Valve, Top G Steel Valve, 1 Steel - 1018 # 0.0450 lb # 0.0450 lb

Top

3 G Valve Plate, Pin G Valve Plate, 4 Commodity # 0.0010 lb # 0.0040 lb

Pin Pricing

2 G Gasket, Front Cover G Gasket, 1 ## 0.0265 lb # 0.0265 lb

Front Cover

3 G Gasket, Front Cover, G Gasket, 1 OVERMOLDE # 0.0000 lb # 0.0000 lb

Material Front Cover, D STEEL

Material

2 G Front Cover Asm. G Front Cover 1 ## 0.7678 lb # 0.7678 lb

Asm.

3 G Front Cover, Wash G Front 1 Aluminum- # 0.7465 lb # 0.7465 lb

Cover, Wash Si8Cu3Fe

4 G Front Cover, Machined G Front 1 # 0.7465 lb # 0.7465 lb

Cover, 

Machined

5 G Front Cover-Trimmed G Front 1 Aluminum- # 0.7465 lb # 0.7465 lb

Cover- Si8Cu3Fe

Trimmed

6 G Front Cover Asm, Casting G Front Cover 1 # 0.7465 lb # 0.7465 lb

Asm, Casting

7 G Front Cover-Alum Mtl G Front 1 A380 ## 0.7465 lb ## 0.7465 lb

Cover-Alum 

Mtl

3 G Seal, Front Cover G Seal, Front 1 Commodity # 0.0155 lb # 0.0155 lb

Cover Pricing

3 G Snap-ring, Seal Front Cover G Snap-ring, 1 # 0.0040 lb # 0.0040 lb

Seal Front 

Cover

3 G Dust Seal, Cloth, Front G Dust Seal, 1 # 0.0018 lb # 0.0018 lb

Cover Cloth, Front 

Cover

2 G Steel Valve, AC Pump G Steel Valve, 1 Steel - 1040 ## 0.0322 lb # 0.0322 lb

AC Pump

Design Profit ®
Page 

5 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

3 G Steel Valve, AC Pump, G Steel Valve, 0.0322 lb 0.0322 lb

Deburred AC Pump, 

Deburr-1

4 G Steel Valve, AC Pump, G Steel Valve, 1 Steel - 1040 # 0.0322 lb # 0.0322 lb

Stamped AC Pump, 

stamped

5 G Steel Valve, AC Pump, G Steel Valve, 1 Steel - 1040 # 0.0322 lb # 0.0322 lb

Material AC Pump, 

Material

2 G Valve Plate, Rear Cover G Valve Plate, 1 ## 0.3490 lb # 0.3490 lb

Rear Cover

3 G Valve Plate, Base, Rear G Valve Plate, 1 # 0.2950 lb # 0.2950 lb

Base, Rear

4 G Valve Plate, Base, Wash, G Valve Plate, 1 # 0.2950 lb # 0.2950 lb

Rear Base, Wash, 

Rear

5 G Valve Plate, Base, G Valve Plate, 1 # 0.2950 lb # 0.2950 lb

Trimmed Rear Base, 

Trimmed, 

Rear

6 G Steel Valve, Valve Plate G Steel Valve, 1 Steel - 1018 # 0.2950 lb # 0.2950 lb

Base, Rear Valve Plate 

Base, Rear

3 G Valve Plate, Valve G Valve Plate, 1 Steel - 1040 # 0.0050 lb # 0.0050 lb

Valve

4 G Valve Plate, Valve G Valve Plate, 1 Steel - 1040 # 0.0050 lb # 0.0050 lb

Valve, 

Deburred

5 G Valve Plate, Valve G Valve Plate, 1 Steel - 1040 # 0.0050 lb # 0.0050 lb

Valve, 

Stamped

6 G Valve Plate, Valve G Valve Plate, 1 Steel - 1040 # 0.0050 lb # 0.0050 lb

Valve

3 G Valve Plate, Top G Valve Plate, 1 # 0.0450 lb # 0.0450 lb

Top

4 G Valve Plate, Top, Deburred G Valve Plate, 1 Steel - 1018 # 0.0450 lb # 0.0450 lb

Top, Deburred

5 G Valve Plate, Top, Stamped G Valve Plate, 1 # 0.0450 lb # 0.0450 lb

Top, Stamped

6 G Steel Valve, Top G Steel Valve, 1 Steel - 1018 # 0.0450 lb # 0.0450 lb

Top

Design Profit ®

Page 6 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

3 G Valve Plate, Pin G Valve Plate, 4 Commodity 0.0010 lb # 0.0040 lb

Pin Pricing

2 G Gasket, Rear Cover G Gasket, 1 ## 0.0250 lb # 0.0250 lb

Rear Cover

3 G Gasket, Rear Cover, G Gasket, 1 OVERMOLDE # 0.0000 lb # 0.0000 lb

Material Rear Cover, D STEEL

Material

2 G Rear Cover Asm G Rear Cover 1 ## 0.8741 lb # 0.8741 lb

Asm

3 G Rear Cover, Washed G Rear Cover, 1 # 0.8418 lb # 0.8418 lb

Washed

4 G Rear Cover, Mach G Rear Cover, 1 # 0.8418 lb # 0.8418 lb

Mach

5 G Rear Cover, Trimmed G Rear Cover, 1 Aluminum- # 0.8418 lb # 0.8418 lb

Trimmed Si8Cu3Fe

6 G Rear Cover, Casting G Rear Cover, 1 # 0.8418 lb # 0.8418 lb

Casting

7 G Rear Cover, Alum Mtl G Rear Cover, 1 Aluminum ## 0.8418 lb ## 0.8418 lb

Alum Mtl A380

3 G O-ring, Plug, Rear Cover G O-ring, Plug, 1 # 0.0001 lb # 0.0001 lb

Rear Cover

3 G Plug A G Plug Asm. , Rear Cover sm. , Rear Cover G Plug A G Plug Asm. , 1 Commodity Commodity # 0.0322 lb 0.0322 lb # 0.0322 lb 0.0322 lb

Rear Cover Pricing

2 G Bolt, Front Cover to Rear G Bolt, Front 5 Commodity ## 0.0810 lb # 0.4050 lb

Cover to Rear Pricing

1 G Magnet Asm., AC Clutch G Magnet 1 # 0.8230 lb # 0.8230 lb

Asm., AC 

Clutch

2 G Magnet Asm, Potted G Magnet 1 ## 0.8230 lb # 0.8230 lb

Asm, Potted

3 G Magnet Asm, Housing, G Magnet 1 # 0.0000 lb # 0.0000 lb

Weldment, Washed Asm, 

Housing, 

Weldment, 

Washed

4 G Magnet Asm, Housing, G Magnet 1 # 0.0000 lb # 0.0000 lb

Weldment Asm, 

Housing, 

Weldment

Design Profit ®
Page 

7 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

G Magnet Asm, Housing, G Magnet # 0.0000 lb 0.0000 lb

Washed Asm, 

Housing, 

Washed

6 G Magnet Asm, Housing, G Magnet 1 Steel - 1008 # 0.0000 lb # 0.0000 lb

Deburred Asm, 

Housing, 

Deburred

7 G Magnet Asm, Housing, G Magnet 1 ## 0.0000 lb ## 0.0000 lb

Machined Asm, 

Housing, 

Machined

8 G Magnet Asm, Housing G Magnet 1 # 0.0000 lb # 0.0000 lb

Formed Asm, Housing 

Formed

9 G Magnet Asm, Housing, G Magnet 1 Steel - 1008 ### 0.0000 lb ## 0.0000 lb

Material Asm, Housing, 

Material

5 G Magnet Asm, Backing G Magnet 1 Steel - 1018 # 0.0000 lb # 0.0000 lb

Plate Asm, Backing 

Plate

6 G Magnet Asm, Backing G Magnet 1 # 0.0000 lb # 0.0000 lb

Plate, Deburred Asm, Backing 

Plate, 

Deburred

7 G Magnet Asm, Backing G Magnet 1 ## 0.0000 lb ## 0.0000 lb

Plate, Stamped Asm, Backing 

Plate, 

Stamped

8 G Magnet Asm, Backing Plate, G Magnet 1 Steel - 1008 # 0.0000 lb # 0.0000 lb

Material Asm, Backing 

Plate, Material

3 G Magnet Asm, Coil G Magnet 1 # 0.8230 lb # 0.8230 lb

w/connector Asm, Coil 

w/connector

4 G Magnet Asm, Coil G Magnet 1 Copper # 0.8230 lb # 0.8230 lb

Asm, Coil

5 G Magnet Asm, Coil Material G Magnet # Copper Wire # 0.0000 lb # 0.0000 lb

Asm, Coil 20 AWG

Material

4 Flux, Solder Flux, Solder 1 # 0.0000 lb # 0.0000 lb

Design Profit ®
Page 

8 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

G Magnet Asm, Connector G Magnet Commodity # 0.0000 lb 0.0000 lb

Asm, Pricing

Connector

4 Solder Solder 1 # 0.0000 lb # 0.0000 lb

3 G Magnet Asm, Liner G Magnet 1 ABS # 0.0000 lb # 0.0000 lb

Asm, Liner

3 Adhesive, Liquid Adhesive, 1 # 0.0000 lb # 0.0000 lb

Liquid

3 G Magnet Asm, Potting G Magnet 1 Epoxy - High # 0.0000 lb # 0.0000 lb

Material Asm, Potting Strength

Material

3 Paint Paint 1 # 0.0000 lb # 0.0000 lb

2 G Magnet Asm, Harness G Magnet 1 ## 0.0000 lb # 0.0000 lb

Pigtail Asm, Harness 

Pigtail

3 G Magnet Asm, Pigtail G Magnet 1 Commodity # 0.0000 lb # 0.0000 lb

Connector 1 w/ overmolded Asm, Pigtail Pricing

wi Connector 1

3 G magnet Asm, Pigtail G magnet 1 Commodity # 0.0000 lb # 0.0000 lb

Connector 2 Asm, Pigtail Pricing

Connector 2

3 G Magnet Asm, Pigtail G Magnet Asm, Pigtail G Magnet G Magnet 1 Commodity Commodity # 0.0000 lb 0.0000 lb # 0.0000 lb 0.0000 lb

Connector 2 Clip Asm, Pigtail Pricing

Connector 2 

Clip

2 Adhesive, Liquid Adhesive, 1 ## 0.0000 lb # 0.0000 lb

Liquid

1 G Snap-ring, AC Magnet G Snap-ring, 1 Commodity # 0.0124 lb # 0.0124 lb

AC Magnet Pricing

1 G Clutch Pully Asm G Clutch Pully 1 # 2.1793 lb # 2.1793 lb

Asm

2 G Clutch Pulley, Machined G Clutch 1 ## 1.9100 lb # 1.9100 lb

Final Pulley, 

Machined 

Final

3 G Clutch Pulley, Paint G Clutch 1 # 1.9100 lb # 1.9100 lb

Pulley, Paint

4 G Clutch Pulley, Washed G Clutch 1 # 1.9100 lb # 1.9100 lb

Pulley, 

Washed

Design Profit ®

Page 9 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

G Clutch Pulley, Machined G Clutch # 1.9100 lb 1.9100 lb

Pulley, 

Machined

6 G Clutch Pulley, Trimmed G Clutch 1 # 1.9100 lb # 1.9100 lb

Pulley, 

Trimmed

7 G Clutch Pulley w/gates and G Clutch 1 ## 1.9100 lb ## 1.9100 lb

runners Pulley

w/gates and 

runners

8 G Clutch Pulley, Sand Cast G Clutch 1 # 1.9100 lb # 1.9100 lb

Pulley, Sand 

Cast

9 G Clutch Pulley, Steel Mtl G Clutch 1 Nodular Iron ### 1.9100 lb ## 1.9100 lb

Pulley, Steel 

Mtl

9 G Clutch Pulley Casting G Clutch 1 ### 0.0000 lb ## 0.0000 lb

Energy Pulley Casting 

Energy

9 G Clutch Pulley Mold Sand G Clutch 1 ### 0.0000 lb ## 0.0000 lb

Lost Pulley Mold 

Sand Lost

2 G Clutch Pully, Friction G Clutch Pully, 1 ## 0.0058 lb # 0.0058 lb

Material Friction 

Material

2 G Clutch Pulley, Bearing G Clutch 1 Commodity ## 0.2635 lb # 0.2635 lb

Pulley, Pricing

Bearing

1 G Snap-ring, AC Hub G Snap-ring, 1 Commodity # 0.0121 lb # 0.0121 lb

AC Hub Pricing

1 G Shim, Clutch Hub G Shim, Clutch 2 Commodity # 0.0008 lb # 0.0016 lb

Hub Pricing

1 G Clutch Hub Asm G Clutch Hub 1 # 0.9800 lb # 0.9800 lb

Asm

2 G Clutch Hub, Rivet Pin, M5 G Clutch Hub, 3 Commodity ## 0.0045 lb # 0.0135 lb

Rivet Pin, M5 Pricing

2 G Clutch Hub, Isolator, G Clutch Hub, 1 ## 0.3400 lb # 0.3400 lb

Painted Asm Isolator, 

Painted Asm

3 G Clutch Hub, Isolator, Insert G Clutch Hub, 1 # 0.3400 lb # 0.3400 lb

Molded Asm Isolator, 

Insert Molded 

Asm

Design Profit ®
Page 

# of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

G Clutch Hub, Isolator, Inner, G Clutch Hub, Steel - 1018 # 0.1570 lb 0.1570 lb

Washed Isolator, 

Inner, Washed

5 G Clutch Hub, Isolator, Inner, G Clutch Hub, 1 Steel - 1018 # 0.1570 lb # 0.1570 lb

Deburred Isolator, 

Inner, 

Deburred

6 G Clutch Hub, Isolator, Inner, G Clutch Hub, 1 Steel - 1018 # 0.1570 lb # 0.1570 lb

Machined Isolator, 

Inner, 

Machined

7 G Clutch Hub, Isolator, Inner, G Clutch Hub, 1 Steel - 1018 ## 0.1570 lb ## 0.1570 lb

Stamped Isolator, 

Inner, 

Stamped

8 G Clutch Hub, Isolator, Inner, G Clutch Hub, 1 Steel - 1018 # 0.1570 lb # 0.1570 lb

Stell Isolator, Inner, 

Steel

4 G Clutch Hub, Isolator, G Clutch Hub, 1 Steel - 1018 # 0.1156 lb # 0.1156 lb

Outer, Washed Isolator, 

Outer, 

Washed

5 G Clutch Hub, Isolator, G Clutch Hub, Isolator, G Clutch Hub, G Clutch Hub, 1 Steel - 1018 Steel - 1018 # 0.1156 lb 0.1156 lb # 0.1156 lb 0.1156 lb

Outer, Deburred Isolator, 

Outer, 

Deburred

6 G Clutch Hub, Isolator, G Clutch Hub, 1 Steel - 1018 # 0.1156 lb # 0.1156 lb

Outer, Stamped Isolator, 

Outer, 

Stamped

7 G Clutch Hub, Isolator, Outer, G Clutch Hub, 1 Steel - 1018 ## 0.1156 lb ## 0.1156 lb

Steel Isolator, Outer, 

Steel

4 G Clutch Hub, Isolator, SBR G Clutch Hub, 1 SBR # 0.0674 lb # 0.0674 lb

Isolator, SBR

2 G Clutch Hub, Washer, M5 G Clutch Hub, 3 Commodity ## 0.0006 lb # 0.0018 lb

Washer, M5 Pricing

2 G Clutch Hub, Face G Clutch Hub, 1 Steel - 1018 ## 0.5067 lb # 0.5067 lb

Face

3 G Clutch Hub, Face, Washed G Clutch Hub, 1 Steel - 1018 # 0.5067 lb # 0.5067 lb

Face, Washed

Design Profit ®
Page 

# of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

G Clutch Hub, Face, G Clutch Hub, Steel - 1018 # 0.5067 lb 0.5067 lb

Deburred Face, 

Deburred

5 G Clutch Hub, Face, G Clutch Hub, 1 Steel - 1018 # 0.5067 lb # 0.5067 lb

Machined Face, 

Deburred-1

6 G Clutch Hub, Face, G Clutch Hub, 1 Steel - 1018 # 0.5067 lb # 0.5067 lb

Stamped Face, 

Stamped

7 G Clutch Hub, Face, Steel G Clutch Hub, 1 Steel - 1018 ## 0.5067 lb ## 0.5067 lb

Face, Steel

2 G Clutch Hub, Splined Hub, G Clutch Hub, 1 Steel - 1018 ## 0.1015 lb # 0.1015 lb

Painted Splined Hub, 

Painted

3 G Clutch Hub, Splined Hub, G Clutch Hub, 1 Steel 1018 # 0.1015 lb # 0.1015 lb

Washed Splined Hub, 

Washed

4 G Clutch Hub, Splined Hub, G Clutch Hub, 1 Steel 1018 # 0.1015 lb # 0.1015 lb

Broached Splined Hub, 

Broached

5 G Clutch Hub, Splined Hub, G Clutch Hub, 1 Steel - 1018 # 0.1015 lb # 0.1015 lb

CNC Turned Splined Hub, 

CNC Turned

6 G Clutch Hub, Center Hub, G Clutch Hub, 1 Steel - 1018 # 0.1015 lb # 0.1015 lb

Splined, Steel Bar Center Hub, 

Splined, Steel 

Bar

2 G Clutch Hub, Rivet Pin, M6 G Clutch Hub, 3 Commodity ## 0.0055 lb # 0.0165 lb

Rivet Pin, M6 Pricing

1 G Bolt, Clutch Hub G Bolt, Clutch 1 Commodity # 0.0130 lb # 0.0130 lb

Hub Pricing

1 G Clutch Hub, Cover, Molded G Clutch Hub, 1 # 0.1250 lb # 0.1250 lb

Cover, 

Molded

2 G Clutch Hub, Cover, Material G Clutch Hub, 1 PBT GF20 ## 0.0000 lb # 0.0000 lb

Cover, Material

1 G Bolt, AC Clutch Hub Cover G Bolt, AC 3 Commodity # 0.0042 lb # 0.0126 lb

Clutch Hub Pricing

Cover

1 G Bracket, AC Electrical, G Bracket, AC 1 Steel - 1008 # 0.0060 lb # 0.0060 lb

Zinc Plated Electrical, 

Zinc Plated

Design Profit ®
Page 

# of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

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

(Total)

G Bracket, AC Electrical, G Bracket, AC 1 Steel - 1008 # 0.0060 lb # 0.0060 lb

Washed Electrical, 

Washed

3 G Bracket, AC Electrical, G Bracket, AC 1 Steel - 1008 # 0.0060 lb # 0.0060 lb

Stamped Electrical, 

Stamped

4 G Bracket, AC Electrical, Steel G Bracket, AC 1 Steel - 1008 # 0.0060 lb # 0.0060 lb

Electrical, 

Steel

1 G Bolt, Bracket, AC Electrical G Bolt, 1 Commodity # 0.0055 lb # 0.0055 lb

Bracket, AC Pricing

Electrical

0 G Bolt, Short, AC Asm to G Bolt, Short, 1 Commodity # 0.0403 lb # 0.0403 lb

Hoses AC Asm to Pricing

Hoses

0 G Bolt, Long, AC Asm. to G Bolt, Long, 1 Commodity # 0.0940 lb # 0.0940 lb

Bracket AC Asm. to Pricing

Bracket

Assembly Totals Report Totals Preassembled Totals

Analyzed Subs: # Piece Cost (Total): # Analyzed Subs:

Unanalyzed Subs: # Unanalyzed Subs:

Weight (Total): 12.9127 lb

Parts: # Parts:

Fasteners: # Fasteners:

Parts+Unanaly# zed: Parts+Unanalyzed:

Design Profit ®

Page # of #
Copyright 2005© Munro & Associates, Inc.
0.8607 lb

0.9315 lb

0.0200 lb

1.7750 lb









0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

1.9100 lb

1.9100 lb

1.9100 lb

0.0000 lb

0.0000 lb

0.1570 lb

0.1570 lb

0.5067 lb



Indented Bill of Materials

G Swash Plate, AC Pump

Level Symbol Name Number Qty Material Piece Cost Weight Piece Cost 

(Total)

G Swash Plate, AC G Swash Plate, 1 0.3903 lb Pump-Machined AC

Pump-Machined

1 G Swash Plate, AC Pump-Trimed G Swash Plate, 1 $0.26 0.3903 lb

AC Pump-Trimed

2 G Swash Plate, AC G Swash Plate, 1 $0.26 0.3903 lb

Pump-pretrim AC Pump-pretrim

3 G Swash Plate, AC Pump-shake G Swash Plate, 1 $0.26 0.3903 lb

out AC Pump-shake 

out

4 G Swash Plate, AC Pump-Cast G Swash Plate, AC 1 Nodular Iron $0.20 0.3903 lb

Material Pump-Cast 

Material

4 G Swash Plate, AC Pump-Energy G Swash Plate, AC 1 $0.03 0.0000 lb

Pump-Energy

4 G Swash Plate, AC Pump-Lost G Swash Plate, AC 1 Mold Sand $0.03 0.0000 lb

Sand Pump-Lost Sand

Assembly Totals Report Totals Preassembled Totals

Analyzed Subs: 4 Piece Cost (Total): Analyzed Subs: 0

Unanalyzed Subs: 0 Unanalyzed Subs: 0

Weight (Total): 0.3903 lb

Parts: 3 Parts: 0

Fasteners: 0 Fasteners:0

Parts+Unanalyzed: 3 Parts+Unanalyzed: 0

Design Profit®

Page 1 of 1
Copyright 2005© Munro & Associates, Inc.
Piece Cost Weight (Total)

$0.26 0.3903 lb

# 0.3903 lb

$0.26 0.3903 lb

$0.26 0.3903 lb

$0.20 0.3903 lb

$0.03 0.0000 lb

$0.03 0.0000 lb

Assembly Report

G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Tool G AC Systems First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

$0.00 Subassembly G AC Systems G AC Pump Asm. G AC Pump Asm. 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

$0.00 Tool G AC Pump Asm. First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

$0.00 Subassembly G AC Pump Asm. G Center Pump Asm. G Center Pump 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Tool G Center Pump First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Subassembly G Center Pump G Rear Pump Housing, Asm. G Rear Pump 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Asm. Housing, Asm.

$0.00 Tool G Rear Pump First Fixture 0.0000 sec 0.0000 sec 0 $0.00 $0.00 1 $0.00

Housing, Asm.

$0.00 P.-P. Part G Rear Pump G Rear Pump Housing, Machined G Rear Pump 3.0000 sec 3.0000 sec 3 $0.00 $0.00 1 $0.00

Housing, Asm. Housing, 

Machined

$0.00 Tool G Rear Pump CNC Machine 0.0000 sec 0.0000 sec 0 $0.00 $0.00 1 $0.00

Housing, 

Machined

$43.52 P.-P. Part G Rear Pump G Rear Pump Housing-Trimmed G Rear Pump 4.0000 sec 4.0000 sec 4 $0.00 $0.00 1 $0.00

Housing, Housing-Trimmed

Machined #

$43.52 Tool G Rear Pump Trim Press 0.0000 sec 0.0000 sec 0 $0.00 $0.00 1 $0.00

Housing-Trimmed

$43.52 P.-P. Part G Rear Pump G Rear Pump Housing-Cast G Rear 0.0000 sec 80.9600 sec 80.96 $0.00 $0.98 1 $0.00

Housing-Trimmed Housing-Cast

$43.52 Tool G Rear Pump Casting Equipment 0.0000 sec 0.0000 sec 0 $0.00 $0.00 1 $0.00

Housing-Cast

- - - NEED RAW MATERIAL - - - - - - -

REQUIRED

- - - Need cycle time - - - - - - -

$43.52 Part G Rear Pump G Front Cover-Raw Material G Rear 0.0000 sec 106.5600 106.56 $0.00 $1.29 1 $0.00

Housing-Cast Housing-Raw sec

Material

$0.00 Operation G Rear Pump Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.00 1 $0.00

Housing, 

Machined

Design Profit ®

Page 1 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Operation G Rear Pump Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.00 1 $0.00

Housing, 

Machined

- - - Front Face - - - - - - -

$0.00 Material Mod. G Rear Pump Turn End Face 60-100mm 6.0000 sec 6.0000 sec 6 $0.00 $0.00 1 $0.00

Housing, 

Machined 60.00

$0.00 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Rear Pump Turn OD Med 60-100mm 3.0000 sec 3.0000 sec 3 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Rear Pump Cut Groove Large 5.0000 sec 5.0000 sec 5 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Rear Pump Chamfer OD 2.0000 sec 2.0000 sec 2 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Rear Pump Spot Face Small 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.00 5 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.00 4 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Rear Pump Bore Hole 30-60mm 2.0000 sec 2.0000 sec 2 $0.00 $0.00 5 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.00 4 $0.00

Housing, 

Machined

Design Profit ®

Page 2 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Rear Pump Hone Hole 2 inch depth 3.0000 sec 3.0000 sec 3 $0.00 $0.00 5 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.00 4 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.00 1 $0.00

Housing, 

Machined

- - - Step multi-tool - - - - - - -

$0.00 Material Mod. G Rear Pump Drill Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.00 5 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Rear Pump Drill Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.00 3 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Rear Pump Drill Hole 30 - 60mm 2.0000 sec 2.0000 sec 2 $0.00 $0.00 1 $0.00

Housing, 

Machined

- - - Center Bore - - - - - - -

$0.00 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Rear Pump Bore Hole 30-60mm 2.0000 sec 2.0000 sec 2 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Rear Pump Spot Face 0.5000 sec 0.5000 sec 0.5 $0.00 $0.00 1 $0.00

Housing, 

Machined 19.5

Design Profit ®

Page 3 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Operation G Rear Pump Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump Part Manipulation 3.0000 sec 3.0000 sec 3 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.00 1 $0.00

Housing, 

Machined

- - - Back Face - - - - - - -

$0.00 Material Mod. G Rear Pump Turn OD Med 60-100mm 3.0000 sec 3.0000 sec 3 $0.00 $0.00 1 $0.00

Housing, 28

Machined

$0.00 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Rear Pump Spot Face 2.0000 sec 2.0000 sec 2 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Rear Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.00 3 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Rear Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.00 2 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Rear Pump Chamfer OD sml 1.0000 sec 1.0000 sec 1 $0.00 $0.00 3 $0.00

Housing, 

Machined

- - - Dual Angle Chamfer on 5 Bore - - - - - - -

Holes

$0.00 Operation G Rear Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.00 1 $0.00

Housing, 

Machined

Design Profit ®

Page 4 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.00 1 $0.00

Housing, 

Machined

- - - Combo Tool Dual Chamfer - - - - - - -

$0.00 Material Mod. G Rear Pump Chamfer ID 1.0000 sec 1.0000 sec 1 $0.00 $0.00 5 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.00 4 $0.00

Housing, 

Machined

- - - 1 Wash Cycles thru machining - - - - - - -

$0.00 Operation G Rear Pump Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.00 1 $0.00

Housing, 

Machined 13

$0.00 Operation G Rear Pump Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump Wash Part 5.0000 sec 5.0000 sec 5 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Rear Pump Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Subassembly G Rear Pump G Bearing, Needle, AC Pump G Bearing, 5.0000 sec 5.0000 sec 5 $0.00 $0.00 1 $0.00

Housing, Asm. Needle, AC 

32 Pump

$0.00 Tool G Rear Pump Press 0.0000 sec 0.0000 sec 0 $0.00 $0.00 1 $0.00

Housing, Asm.

$0.00 Fastening G Rear Pump Press Together 3.0000 sec 3.0000 sec 3 $0.00 $0.00 1 $0.00

Housing, Asm.

$0.00 Operation G Rear Pump Change Tool 2.0000 sec 2.0000 sec 2 $0.00 $0.00 1 $0.00

Housing, Asm.

$0.00 Material Mod. G Rear Pump Swage 1.0000 sec 1.0000 sec 1 $0.00 $0.00 1 $0.00

Housing, Asm.

$0.00 Part G Rear Pump G Dowel, Small, Rear Housing G Dowel, Small, 6.0000 sec 6.0000 sec 6 $0.00 $0.00 3 $0.00

Housing, Asm. Rear Housing

$0.00 Tool G Rear Pump Hand Tool 3.0000 sec 3.0000 sec 3 $0.00 $0.00 1 $0.00

Housing, Asm.

Design Profit ®

Page 5 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Operation G Rear Pump Press part 3.0000 sec 3.0000 sec 3 $0.00 $0.00 3 $0.00

Housing, Asm.

$0.00 Operation G Rear Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.00 1 $0.00

Housing, Asm.

$0.00 Part G Rear Pump G Oing, Housing, AC Pump G Oing, Housing, 6.0000 sec 6.0000 sec 6 $0.00 $0.00 1 $0.00

Housing, Asm. AC Pump

$0.00 Operation G Rear Pump Set O-ring in Place 2.0000 sec 2.0000 sec 2 $0.00 $0.00 1 $0.00

Housing, Asm.

375.02

$0.00 P.-P. Part G Center Pump G Spacer, Shaft, Large G Spacer, Shaft, 6.0000 sec 6.0000 sec 6 $0.00 $0.00 1 $0.00

Asm. Large

$0.00 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec 1 $0.00 $0.00 1 $0.00

Asm.

$0.00 Subassembly G Center Pump G Thrust Bearing, Shaft G Thrust Bearing, 6.0000 sec 6.0000 sec 6 $0.00 $0.00 1 $0.00

Asm. Shaft

$0.00 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec 1 $0.00 $0.00 1 $0.00

Asm.

$0.00 P.-P. Part G Center Pump G Spacer, Shaft, Small G Spacer, Shaft, 6.0000 sec 6.0000 sec 6 $0.00 $0.00 1 $0.00

Asm. Small

$0.00 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec 1 $0.00 $0.00 1 $0.00

Asm.

$0.00 Subassembly Subassembly G Center Pump G Center Pump G Shaft and Swash Plate Asm. G Shaft and Swash Plate Asm. G Shaft and G Shaft and 6.0000 sec 6.0000 sec 6.0000 sec 6.0000 sec 6 $0.00 $0.00 1 $0.00

Asm. Swash Plate 

Asm. 402.02

$0.00 Tool G Shaft and First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Swash Plate 

Asm.

$0.00 P.-P. Part G Shaft and G Shaft, AC Pump G Shaft, AC 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Swash Plate Pump

Asm.

$0.00 Tool G Shaft, AC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Pump

$0.00 P.-P. Part G Shaft, AC G Shaft, AC Pump, Trimmed G Shaft, AC 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Pump Pump, Trimmed

$0.00 Operation G Shaft, AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Pump

$0.00 Operation G Shaft, AC Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Pump

- - - BROACH SPLINE - - - - - - -

$0.00 Operation G Shaft, AC Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Pump

$0.00 Operation G Shaft, AC Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Pump

Design Profit ®

Page 6 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Operation G Shaft, AC Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Pump

$0.00 Operation G Shaft, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Pump

- - - 1 Wash Cycles thru machining - - - - - - -

$0.00 Operation G Shaft, AC Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Pump

$0.00 Operation G Shaft, AC Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Pump

$0.00 Operation G Shaft, AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Pump

$0.00 Operation G Shaft, AC Wash Part 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Pump

$0.00 Operation G Shaft, AC Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Pump

$0.00 P.-P. Part G Shaft and G Swash Plate, AC Pump G Swash Plate, 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Swash Plate AC Pump

Asm.

$0.00 Tool G Swash Plate, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

AC Pump

$0.00 Operation G Swash Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

AC Pump

$0.00 Operation G Swash Plate, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

AC Pump

$0.00 Material Mod. Material Mod. G Swash Plate, G Swash Plate, Broach Steel 1 ft lng tool Broach Steel 1 ft lng tool 1.5000 sec 1.5000 sec 1.5000 sec 1.5000 sec $0.00 $0.00 1 $0.00

AC Pump

- - - 1 Wash Cycles thru machining - - - - - - -

$0.00 Operation G Swash Plate, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

AC Pump

$0.00 Operation G Swash Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

AC Pump

$0.00 Operation G Swash Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

AC Pump

$0.00 Operation G Swash Plate, Wash Part 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

AC Pump

$0.00 Operation G Swash Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

AC Pump

$0.00 Tool G Shaft and Press 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Swash Plate 

Asm.

Design Profit ®

Page 7 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Fastening G Shaft and Press Together 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Swash Plate 

Asm.

$0.00 Subassembly G Center Pump G Piston Asm. AC Compressor G Piston Asm. 6.0000 sec 6.0000 sec $0.00 $0.00 5 $0.00

Asm. AC Compressor

$0.00 Tool G Piston Asm. First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 5 $0.00

AC Compressor

$0.00 P.-P. Part G Piston Asm. G Piston, AC Compressor G Piston, AC 3.0000 sec 3.0000 sec $0.00 $0.00 5 $0.00

AC Compressor Compressor

$0.00 Tool G Piston, AC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 P.-P. Part G Piston, AC G Piston, AC Compressor, G Piston, AC 3.0000 sec 3.0000 sec $0.00 $0.00 5 $0.00

Compressor Trimmed Compressor, 

Trimmed

$0.00 Tool G Piston, AC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 5 $0.00

Compressor, 

Trimmed

$0.00 P.-P. Part G Piston, AC G Piston, AC Compressor, Cast G Piston, AC 3.0000 sec 3.0000 sec $0.00 $0.00 5 $0.00

Compressor, Compressor, 

Trimmed Cast

$0.00 Tool G Piston, AC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 5 $0.00

Compressor, 

Cast

- - - NEED RAW MATERIAL - - - - - - -

REQUIRED

$0.00 P.-P. Part G Piston, AC G Piston, AC Compressor, Raw G Piston, AC 3.0000 sec 3.0000 sec $0.00 $0.00 5 $0.00

Compressor, Material Compressor, 

Cast Raw Material

$0.00 Operation G Piston, AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Operation G Piston, AC Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 5 $0.00

Compressor

- - - END FACES - - - - - - -

$0.00 Material Mod. G Piston, AC Turn End Face 30-60mm 4.0000 sec 4.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Material Mod. G Piston, AC Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Operation G Piston, AC Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 5 $0.00

Compressor

Design Profit ®

Page 8 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Operation G Piston, AC Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Operation G Piston, AC Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Material Mod. G Piston, AC Turn End Face 30-60mm 4.0000 sec 4.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Material Mod. G Piston, AC Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 5 $0.00

Compressor

- - - OUTSIDE FEATURES - - - - - - -

$0.00 Operation G Piston, AC Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Operation G Piston, AC Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Operation G Piston, AC Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Material Mod. G Piston, AC Turn OD 30-60mm 2.0000 sec 2.0000 sec $0.00 $0.00 5 $0.00

Compressor

- - - SPECIAL KNURLED ENDS - - - - - - -

$0.00 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Material Mod. G Piston, AC Knurl OD 2.0000 sec 2.0000 sec $0.00 $0.00 5 $0.00

Compressor

- - - INSIDE FEATURES INSIDE FEATURES - - - - - - -

- - - SQUARE PADS - - - - - - -

$0.00 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Material Mod. G Piston, AC Spot Face 2.0000 sec 2.0000 sec $0.00 $0.00 10 $0.00

Compressor

$0.00 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Material Mod. G Piston, AC Spot Face 0.5000 sec 0.5000 sec $0.00 $0.00 10 $0.00

Compressor

- - - BALL SOCKETS - - - - - - -

$0.00 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Material Mod. G Piston, AC Spot Face 2.0000 sec 2.0000 sec $0.00 $0.00 10 $0.00

Compressor

$0.00 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 5 $0.00

Compressor

Design Profit ®

Page 9 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Material Mod. G Piston, AC Spot Face 0.5000 sec 0.5000 sec $0.00 $0.00 10 $0.00

Compressor

- - - 1 Wash Cycles thru machining - - - - - - -

$0.00 Operation G Piston, AC Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Operation G Piston, AC Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Operation G Piston, AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Operation G Piston, AC Wash Part 5.0000 sec 5.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Operation G Piston, AC Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 5 $0.00

Compressor

$0.00 Part G Piston Asm. G Seal, Piston, AC Compressor G Seal, Piston, 6.0000 sec 6.0000 sec $0.00 $0.00 10 $0.00

AC Compressor AC Compressor

$0.00 Operation G Piston Asm. Set O-ring in Place 2.0000 sec 2.0000 sec $0.00 $0.00 10 $0.00

AC Compressor

$0.00 Operation G Piston Asm. Press part 3.0000 sec 3.0000 sec $0.00 $0.00 5 $0.00

AC Compressor

$0.00 P.-P. Part G Center Pump G Bearing, Swash Plate to Piston G Bearing, 6.0000 sec 6.0000 sec $0.00 $0.00 10 $0.00

Asm. Swash Plate to 

Piston

$0.00 Operation G Center Pump Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 10 $0.00

Asm.

$0.00 P.-P. Part P.-P. Part G Center Pump G Center Pump G Spacer, Shaft, Large G Spacer, Shaft, Large G Spacer, Shaft, G Spacer, Shaft, 6.0000 sec 6.0000 sec 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Asm. Large

$0.00 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Subassembly G Center Pump G Thrust Bearing, Shaft G Thrust Bearing, 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Asm. Shaft

$0.00 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 P.-P. Part G Center Pump G Spacer, Shaft, Small G Spacer, Shaft, 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Asm. Small

$0.00 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Part G Center Pump G Gasket, Pump Housing G Gasket, Pump 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Asm. Housing

$0.00 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Asm.

Design Profit ®

Page 10 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Subassembly G Center Pump G Front Pump Housing, Asm G Front Pump 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Asm. Housing, Asm

$0.00 Tool G Front Pump First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Housing, Asm

$0.00 P.-P. Part G Front Pump G Front Pump Housing, G Front Pump 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Housing, Asm Machined Housing, 

Machined

$0.00 Tool G Front Pump First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 P.-P. Part G Front Pump G Front Pump Housing, Trimmed G Front Pump 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Housing, Housing, 

Machined Trimmed

$0.00 Tool G Front Pump First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Trimmed

$0.00 P.-P. Part G Front Pump G Front Pump Housing, Cast G Front Pump 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Housing, Housing, Raw 

Trimmed Material

$0.00 Tool G Front Pump First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Housing, Cast

- - - NEED RAw MAterial - - - - - - -

$0.00 P.-P. Part G Front Pump G Front Pump Housing, Raw G Front Pump 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Housing, Cast Material Housing, Raw 

Material

$0.00 Operation G Front Pump Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

- - - Front Face - - - - - - -

$0.00 Material Mod. G Front Pump Turn End Face 60-100mm 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Turn OD Med 60-100mm 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

Design Profit ®

Page 11 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Cut Groove Large 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Chamfer OD 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Spot Face Small 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 5 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.00 4 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. Material Mod. G Front Pump G Front Pump Bore Hole 30-60mm Bore Hole 30-60mm 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec $0.00 $0.00 5 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.00 4 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Hone Hole 2 inch depth 3.0000 sec 3.0000 sec $0.00 $0.00 5 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.00 4 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

- - - Step multi-tool - - - - - - -

Design Profit ®

Page 12 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Material Mod. G Front Pump Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 5 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Drill Hole 30 - 60mm 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

- - - Center Bore - - - - - - -

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Bore Hole 30-60mm 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Spot Face 0.5000 sec 0.5000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

- - - Back Face - - - - - - -

$0.00 Material Mod. G Front Pump Turn OD Med 60-100mm 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Spot Face 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

Design Profit ®

Page 13 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 3 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 2 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 3 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Tap Hole 0.5000 sec 0.5000 sec $0.00 $0.00 3 $0.00

Housing, 

Machined

- - - Dual Angle Chamfer on 5 Bore Dual Angle Chamfer on 5 Bore - - - - - - -

Holes

$0.00 Operation G Front Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

- - - Combo Tool Dual Chamfer - - - - - - -

$0.00 Material Mod. G Front Pump Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.00 5 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.00 4 $0.00

Housing, 

Machined

- - - Interior Angle Hole - - - - - - -

Design Profit ®

Page 14 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

- - - Port Face - - - - - - -

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Turn End face 1-30mm 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

Design Profit ®

Page 15 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Material Mod. G Front Pump Tap Hole 0.5000 sec 0.5000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Spot Face Small 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Spot Face Small 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

- - - Mounting Holes Mounting Holes - - - - - - -

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Bore Hole 60-100mm 3.0000 sec 3.0000 sec $0.00 $0.00 2 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Spot Face Small 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 2 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Material Mod. G Front Pump Spot Face Small 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 2 $0.00

Housing, 

Machined

Design Profit ®

Page 16 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

- - - 1 Wash Cycles thru machining - - - - - - -

$0.00 Operation G Front Pump Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Wash Part 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Operation G Front Pump Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Housing, 

Machined

$0.00 Subassembly G Front Pump G Bearing, Needle, AC Pump G Bearing, 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Housing, Asm Needle, AC 

Pump

$0.00 Tool G Front Pump Press 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Housing, Asm

$0.00 Fastening G Front Pump Press Together 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Housing, Asm

$0.00 Operation G Front Pump Change Tool 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Housing, Asm

$0.00 Material Mod. G Front Pump Swage 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Housing, Asm

$0.00 Part G Front Pump G Dowel, Large Front Housing G Dowel, Large 6.0000 sec 6.0000 sec $0.00 $0.00 2 $0.00

Housing, Asm Front Housing

$0.00 Tool G Front Pump Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Housing, Asm

$0.00 Operation G Front Pump Press part 3.0000 sec 3.0000 sec $0.00 $0.00 2 $0.00

Housing, Asm

$0.00 Operation G Front Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Housing, Asm

$0.00 Part G Front Pump G Oing, Housing, AC Pump G Oing, Housing, 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Housing, Asm AC Pump

$0.00 Operation G Front Pump Set O-ring in Place 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Housing, Asm

$0.00 Part G Center Pump G Bolt, Front to Rear Housing G Bolt, Front to 6.0000 sec 6.0000 sec $0.00 $0.00 3 $0.00

Asm. Rear Housing

Design Profit ®

Page 17 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Tool G Center Pump 3 Spindle Nut Runner 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Fastening G Center Pump Power Screw 4.0000 sec 4.0000 sec $0.00 $0.00 1 $0.00

Asm.

$42.18 P.-P. Part G AC Pump Asm. G Steel Valve, AC Pump G Steel Valve, 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

AC Pump

$42.18 Tool G Steel Valve, Stamping Press 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

AC Pump

- - - Raw Material Required 0.064 lbs - - - - - - -

from excel

$42.18 Part G Steel Valve, G Steel Valve, AC Pump, G Steel Valve, 0.0000 sec 0.7000 sec $0.00 $0.01 1 $0.00

AC Pump stamped AC Pump, 

stamped

- - - 60 ton press, 4 station prog die - - - - - - -

$0.00 Operation G AC Pump Asm. Align to Housing 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

$0.00 Subassembly G AC Pump Asm. G Valve Plate, Front Cover G Valve Plate, 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Front Cover

$0.00 Tool G Valve Plate, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Front Cover

$0.00 P.-P. Part G Valve Plate, G Valve Plate, Base G Valve Plate, 4.0000 sec 4.0000 sec $0.00 $0.00 1 $0.00

Front Cover Base

$0.00 Tool G Valve Plate, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Base

$0.00 P.-P. Part G Valve Plate, G Valve Plate, Trimmed G Valve Plate, 4.0000 sec 4.0000 sec $0.00 $0.00 1 $0.00

Base Trimmed

$0.00 Tool G Valve Plate, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Trimmed

- - - NEED RAW MATERIAL - - - - - - -

$0.00 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Base

$0.00 Operation G Valve Plate, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Base

- - - GRIND OUTER DIAMETER - - - - - - -

$0.00 Material Mod. G Valve Plate, Gound OD 1 inch 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Base

- - - GRIND SURFACE FACES - - - - - - -

$0.00 Operation G Valve Plate, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Base

$0.00 Material Mod. G Valve Plate, Ground end faces 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Base

Design Profit ®

Page 18 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Operation G Valve Plate, CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Base

$0.00 Material Mod. G Valve Plate, Ground end faces 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Base

- - - 1 Wash Cycles thru machining - - - - - - -

$0.00 Operation G Valve Plate, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Base

$0.00 Operation G Valve Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Base

$0.00 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Base

$0.00 Operation G Valve Plate, Wash Part 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Base

$0.00 Operation G Valve Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Base

$0.00 Operation G Valve Plate, Align to Base 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Front Cover

$0.00 P.-P. Part G Valve Plate, G Valve Plate, Valve G Valve Plate, 4.0000 sec 4.0000 sec $0.00 $0.00 1 $0.00

Front Cover Valve

$0.00 Operation G Valve Plate, Align to Base 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Front Cover

$0.00 P.-P. Part G Valve Plate, G Valve Plate, Top G Valve Plate, 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Front Cover Top

$0.00 Operation G Valve Plate, Insert Pins 2.0000 sec 2.0000 sec $0.00 $0.00 4 $0.00

Front Cover

$0.00 P.-P. Part G Valve Plate, G Valve Plate, Pin G Valve Plate, 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Front Cover Pin

$0.00 Material Mod. G Valve Plate, Swage 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Front Cover

$0.00 Operation G AC Pump Asm. Align to Housing 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

$0.00 Part G AC Pump Asm. G Gasket, Front Cover G Gasket, Front 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Cover

$0.00 Operation G AC Pump Asm. Align to Housing 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

- - - SPACE FOR PRINTING - - - - - - -

- - - SPACE FOR PRINTING - - - - - - -

- - - SPACE FOR PRINTING - - - - - - -

- - - SPACE FOR PRINTING - - - - - - -

- - - SPACE FOR PRINTING - - - - - - -

- - - SPACE FOR PRINTING - - - - - - -

- - - SPACE FOR PRINTING - - - - - - -

Design Profit ®

Page 19 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

- - - SPACE FOR PRINTING - - - - - - -

- - - SPACE FOR PRINTING - - - - - - -

- - - SPACE FOR PRINTING - - - - - - -

- - - SPACE FOR PRINTING - - - - - - -

- - - SPACE FOR PRINTING - - - - - - -

- - - SPACE FOR PRINTING - - - - - - -

- - - SPACE FOR PRINTING - - - - - - -

- - - SPACE FOR PRINTING - - - - - - -

- - - SPACE FOR PRINTING - - - - - - -

- - - SPACE FOR PRINTING - - - - - - -

- - - SPACE FOR PRINTING - - - - - - -

$0.00 Subassembly G AC Pump Asm. G Front Cover Asm. G Front Cover 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Tool G Front Cover First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 P.-P. Part G Front Cover G Front Cover, Machined G Front Cover, 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Asm. Machined

$0.00 Tool G Front Cover, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Machined

$43.52 P.-P. Part G Front Cover, G Front Cover-Trimmed G Front 4.0000 sec 4.0000 sec $0.00 $0.00 1 $0.00

Machined Cover-Trimmed

$43.52 Tool G Front Trim Press 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Cover-Trimmed

$43.52 P.-P. Part P.-P. Part G Front G Front G Front Cover-Cast G Front Cover-Cast G Front G Front 0.0000 sec 0.0000 sec 80.9600 sec 80.9600 sec $0.00 $0.98 1 $0.00

Cover-Trimmed Cover-Cast

$43.52 Tool G Front Casting Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Cover-Cast

- - - NEED RAW MATERIAL - - - - - - -

REQUIRED

$43.52 Part G Front G Front Cover-Raw Material G Front 0.0000 sec 106.5600 $0.00 $1.29 1 $0.00

Cover-Cast Cover-Raw sec

Material

$0.00 Operation G Front Cover, Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Front Cover, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Machined

- - - Front Face - - - - - - -

$0.00 Material Mod. G Front Cover, Turn End face 1-30mm 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Machined

Design Profit ®

Page 20 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Front Cover, Turn OD 30-60mm 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Front Cover, Cut Groove sml 2.0000 sec 2.0000 sec $0.00 $0.00 2 $0.00

Machined

$0.00 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Front Cover, Turn End face 1-30mm 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Front Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Front Cover, Chamfer OD sml 1.0000 sec 1.0000 sec $0.00 $0.00 2 $0.00

Machined

- - - Locationg feature - - - - - - -

$0.00 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Front Cover, Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Front Cover, Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

- - - Inner groove - - - - - - -

$0.00 Material Mod. G Front Cover, Cut Groove sml 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Front Cover, Chamfer OD sml 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Front Cover, Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 5 $0.00

Machined

Design Profit ®

Page 21 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Front Cover, Spot Face 0.5000 sec 0.5000 sec $0.00 $0.00 5 $0.00

Machined

$0.00 Operation G Front Cover, Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Machined

- - - Inside of Outer Lip - - - - - - -

$0.00 Material Mod. G Front Cover, Turn OD Med 60-100mm 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Front Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Front Cover, Turn End Face 60-100mm 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Machined

- - - Inner Bore - - - - - - -

$0.00 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Front Cover, Spot Face 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Front Cover, Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. Material Mod. G Front Cover, G Front Cover, Chamfer ID Chamfer ID 1.0000 sec 1.0000 sec 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Front Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Front Cover, Chamfer OD sml 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Front Cover, Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

- - - Angled Ports - - - - - - -

$0.00 Operation G Front Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Front Cover, Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

Design Profit ®

Page 22 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Operation G Front Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Front Cover, Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

- - - Tab - - - - - - -

$0.00 Operation G Front Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Front Cover, Drill and Tap Hole 1-30mm 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

- - - 1 Wash Cycles thru machining - - - - - - -

$0.00 Operation G Front Cover, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Front Cover, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Front Cover, Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Front Cover, Wash Part 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Front Cover, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Subassembly G Front Cover G Seal, Front Cover G Seal, Front 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Asm. Cover

$0.00 Operation Operation G Front Cover G Front Cover Part Manipulation Part Manipulation 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Tool G Front Cover Press 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Fastening G Front Cover Press Together 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Part G Front Cover G Snap-ring, Seal Front Cover G Snap-ring, Seal 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Asm. Front Cover

$0.00 Operation G Front Cover CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Tool G Front Cover Special Tool 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Fastening G Front Cover Position Part 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Operation G Front Cover CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Asm.

Design Profit ®

Page 23 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Part G Front Cover G Dust Seal, Cloth, Front Cover G Dust Seal, 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Asm. Cloth, Front 

Cover

$0.00 Operation G Front Cover Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Operation G AC Pump Asm. Press part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

$0.00 Operation G AC Pump Asm. Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

$0.00 P.-P. Part G AC Pump Asm. G Steel Valve, AC Pump G Steel Valve, 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

AC Pump

$0.00 Operation G AC Pump Asm. Align to Housing 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

$0.00 Subassembly G AC Pump Asm. G Valve Plate, Rear Cover G Valve Plate, 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Rear Cover

$0.00 Operation G AC Pump Asm. Align to Housing 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

$0.00 Part G AC Pump Asm. G Gasket, Rear Cover G Gasket, Rear 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Cover

$0.00 Operation G AC Pump Asm. Align to Housing 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

$0.00 Subassembly G AC Pump Asm. G Rear Cover Asm. G Rear Cover 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Tool G Rear Cover First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 P.-P. Part G Rear Cover G Rear Cover, Machined G Rear Cover, 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Asm. Machined

$0.00 Tool G Rear Cover, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 P.-P. Part G Rear Cover, G Rear Cover, Trimmed G Rear Cover, 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Machined Trimmed

$0.00 Tool G Rear Cover, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Trimmed

$0.00 P.-P. Part G Rear Cover, G Rear Cover, Cast G Rear Cover, 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Trimmed Cast

$0.00 Tool G Rear Cover, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Cast

- - - NEED RAW MATERIAL - - - - - - -

REQUIRED

$0.00 Part G Rear Cover, G Rear Cover, Raw Material G Rear Cover, 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Cast Raw Material

$0.00 Operation G Rear Cover, Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Rear Cover, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Machined

- - - Back Face - - - - - - -

Design Profit ®

Page 24 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Material Mod. G Rear Cover, Turn End face 1-30mm 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Rear Cover, Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Rear Cover, Spot Face 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Rear Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Rear Cover, Spot Face Small 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Rear Cover, Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 5 $0.00

Machined

$0.00 Operation G Rear Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.00 4 $0.00

Machined

$0.00 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Rear Cover, Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation Operation G Rear Cover, G Rear Cover, Auto Tool Change Auto Tool Change 5.0000 sec 5.0000 sec 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Rear Cover, Tap Hole 0.5000 sec 0.5000 sec $0.00 $0.00 5 $0.00

Machined

$0.00 Operation G Rear Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.00 4 $0.00

Machined

$0.00 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

- - - CENTER BORE - - - - - - -

$0.00 Material Mod. G Rear Cover, Drill and Tap Hole 1-30mm 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Rear Cover, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Rear Cover, Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Rear Cover, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Machined

Design Profit ®

Page 25 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

- - - FRONT SIDE - - - - - - -

$0.00 Material Mod. G Rear Cover, Spot Face 2.0000 sec 2.0000 sec $0.00 $0.00 3 $0.00

Machined

$0.00 Operation G Rear Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

- - - CENTER BORE - - - - - - -

$0.00 Material Mod. G Rear Cover, Spot Face 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Rear Cover, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Rear Cover, Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Rear Cover, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Machined

- - - SIDE MOUNTING HOLES - - - - - - -

$0.00 Material Mod. G Rear Cover, Bore Hole 60-100mm 3.0000 sec 3.0000 sec $0.00 $0.00 2 $0.00

Machined

$0.00 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Material Mod. G Rear Cover, Spot Face Small 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 2 $0.00

Machined

- - - 1 Wash Cycles thru machining - - - - - - -

$0.00 Operation G Rear Cover, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Rear Cover, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Rear Cover, Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Rear Cover, Wash Part 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Operation G Rear Cover, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Machined

$0.00 Part G Rear Cover G O-ring, Plug, Rear Cover G O-ring, Plug, 4.0000 sec 4.0000 sec $0.00 $0.00 1 $0.00

Asm. Rear Cover

$0.00 Operation G Rear Cover Set O-ring in Place 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Subassembly G Rear Cover G Plug Asm. , Rear Cover G Plug Asm. , 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Asm. Rear Cover

$0.00 Tool G Rear Cover Power Tool 4.0000 sec 4.0000 sec $0.00 $0.00 1 $0.00

Asm.

Design Profit ®

Page 26 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Fastening G Rear Cover Power Screw 4.0000 sec 4.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Operation G AC Pump Asm. Press part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

$0.00 Operation G AC Pump Asm. Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

$0.00 Part G AC Pump Asm. G Bolt, Front Cover to Rear G Bolt, Front 6.0000 sec 6.0000 sec $0.00 $0.00 5 $0.00

Cover to Rear

$0.00 Tool G AC Pump Asm. 5 Spindle Nut Runner 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

$0.00 Fastening G AC Pump Asm. Power Screw 4.0000 sec 4.0000 sec $0.00 $0.00 1 $0.00

$0.00 Subassembly G AC Systems G Magnet Asm., AC Clutch G Magnet Asm., 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

AC Clutch

$0.00 Part G AC Systems G Snap-ring, AC Magnet G Snap-ring, AC 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Magnet

$0.00 Operation G AC Systems CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

$0.00 Tool G AC Systems Special Tool 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

$0.00 Fastening G AC Systems Position Part 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

$0.00 Operation G AC Systems CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

$0.00 Subassembly G AC Systems G Clutch Hub Asm. G Clutch Hub 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Tool G Clutch Hub First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 P.-P. Part G Clutch Hub G Cllutch Hub G Cllutch Hub 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Tool G Cllutch Hub First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

$0.00 Part G Clutch Hub G Clutch Hub G AC Clutch Material G AC Clutch Material G AC Clutch G AC Clutch 5.0000 sec 5.0000 sec 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Asm. Material

$0.00 Tool G Clutch Hub Glue Bottle 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Fastening G Clutch Hub Glue in Place 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Operation G Clutch Hub Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Subassembly G Clutch Hub G Bearing, Clutch Hub G Bearing, Clutch 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Asm. Hub

$0.00 Tool G Clutch Hub Press 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Fastening G Clutch Hub Press Together 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Tool G Clutch Hub Stamping Press 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Asm.

Design Profit ®

Page 27 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Operation G Clutch Hub Change Tool 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Material Mod. G Clutch Hub Swage 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Asm.

$0.00 Operation G AC Systems CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

$0.00 Part G AC Systems G Snap-ring, AC Hub G Snap-ring, AC 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Hub

$0.00 Tool G AC Systems Special Tool 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

$0.00 Fastening G AC Systems Position Part 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

$0.00 Operation G AC Systems CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

$0.00 Part G AC Systems G Shim, Clutch Hub G Shim, Clutch 6.0000 sec 6.0000 sec $0.00 $0.00 2 $0.00

Hub

$0.00 Fastening G AC Systems Set In Place 1.0000 sec 1.0000 sec $0.00 $0.00 2 $0.00

$0.00 Subassembly G AC Systems G Outer AC Clutch Hub G Outer AC 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub

$0.00 Tool G Outer AC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub

$0.00 P.-P. Part G Outer AC G Outer AC Clutch Hub, Face G Outer AC 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub Clutch Hub, 

Face

$0.00 Tool G Outer AC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, Face

$0.00 P.-P. Part G Outer AC G Outer AC Clutch Hub, Face, G Outer AC 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, Face Trimmed Clutch Hub, 

Face, Trimmed

$0.00 Tool G Outer AC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Face, Trimmed

$0.00 P.-P. Part G Outer AC G Outer AC Clutch Hub, Face, G Outer AC 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, Trimmed Clutch Hub, 

Face, Trimmed Face, Grind

$0.00 Tool G Outer AC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Face, Trimmed

$0.00 Operation G Outer AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Face, Trimmed

$0.00 Operation G Outer AC Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Face, Trimmed

Design Profit ®

Page 28 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Material Mod. G Outer AC Grind Flat 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Face, Trimmed

$0.00 Operation G Outer AC Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Face, Trimmed

$0.00 Material Mod. G Outer AC Grind Flat 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Face, Trimmed

- - - 1 Wash Cycles thru machining - - - - - - -

$0.00 Operation G Outer AC Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Face, Trimmed

$0.00 Operation G Outer AC Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Face, Trimmed

$0.00 Operation G Outer AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Face, Trimmed

$0.00 Operation G Outer AC Wash Part 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Face, Trimmed

$0.00 Operation G Outer AC Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Face, Trimmed

$0.00 Operation G Outer AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, Face

$0.00 Material Mod. G Outer AC Paint Part 1.6000 sec 1.6000 sec $0.00 $0.00 1 $0.00

Clutch Hub, Face

$0.00 Operation G Outer AC Unload Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, Face

$0.00 Operation G Outer AC Align to Base 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub

$0.00 P.-P. Part G Outer AC G Outer AC Clutch Hub, Isolator G Outer AC 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub Clutch Hub, 

Isolator

$0.00 Tool G Outer AC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Isolator

$0.00 P.-P. Part G Outer AC G Outer AC Clutch Hub, Isolator, G Outer AC 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, Molded Clutch Hub, 

Isolator Isolator, Molded

Design Profit ®

Page 29 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Tool G Outer AC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Isolator, Molded

$0.00 P.-P. Part G Outer AC G Outer AC Clutch Hub, Isolator, G Outer AC 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, Outside Clutch Hub, 

Isolator, Molded Isolator, Outside

$0.00 Tool G Outer AC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Isolator, Outside

$0.00 P.-P. Part G Outer AC G Outer AC Clutch Hub, Isolator, G Outer AC 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, Inside Clutch Hub, 

Isolator, Molded Isolator, Inside

$0.00 Tool G Outer AC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Isolator, Inside

$0.00 Part G Outer AC G Outer AC Clutch Hub, Isolator, G Outer AC 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, Molded Clutch Hub, 

Isolator, Molded Isolator, Rubber

$0.00 Operation G Outer AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Isolator

$0.00 Material Mod. G Outer AC Paint Part 1.6000 sec 1.6000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Isolator

$0.00 Operation Operation G Outer AC G Outer AC Unload Part Unload Part 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Isolator

$0.00 Operation G Outer AC Align to Base 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub

$0.00 P.-P. Part G Outer AC G Outer AC Clutch Hub, Spline G Outer AC 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub Clutch Hub, 

Spline

$0.00 Tool G Outer AC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 P.-P. Part G Outer AC G Outer AC Clutch Hub, Spline G Outer AC 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, Clutch Hub, 

Spline Spline, Paint

$0.00 Tool G Outer AC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

Design Profit ®

Page 30 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 P.-P. Part G Outer AC G Outer AC Clutch Hub, Spline G Outer AC 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, Clutch Hub, 

Spline Spline, Broach

$0.00 Tool G Outer AC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 P.-P. Part G Outer AC G Outer AC Clutch Hub, Spline G Outer AC 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, Clutch Hub, 

Spline Spline, Trimmed

$0.00 Tool G Outer AC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

- - - BAR STOCK 1008 WT. 0.5LBS - - - - - - -

$0.00 Operation G Outer AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Operation G Outer AC Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

- - - STANDOFF SPLINE FACE - - - - - - -

$0.00 Material Mod. G Outer AC Turn end face 1-30mm 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Operation G Outer AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Material Mod. G Outer AC Turn Face Contoured 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

- - - SPLINE HOLE - - - - - - -

$0.00 Operation G Outer AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Material Mod. G Outer AC Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

- - - BACK FACE - - - - - - -

$0.00 Operation G Outer AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

Design Profit ®

Page 31 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Operation G Outer AC Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Material Mod. G Outer AC Turn end face 1-30mm 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Operation G Outer AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Operation G Outer AC Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Material Mod. G Outer AC Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 3 $0.00

Clutch Hub, 

Spline

$0.00 Operation G Outer AC CDI 1.0000 sec 1.0000 sec $0.00 $0.00 2 $0.00

Clutch Hub, 

Spline

$0.00 Operation G Outer AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Material Mod. G Outer AC Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.00 3 $0.00

Clutch Hub, 

Spline

$0.00 Operation Operation G Outer AC G Outer AC CDI 1.0000 sec 1.0000 sec 1.0000 sec 1.0000 sec $0.00 $0.00 2 $0.00

Clutch Hub, 

Spline

- - - 1 Wash Cycles thru machining - - - - - - -

$0.00 Operation G Outer AC Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Operation G Outer AC Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Operation G Outer AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Operation G Outer AC Wash Part 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Operation G Outer AC Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

Design Profit ®

Page 32 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Operation G Outer AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Operation G Outer AC Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Material Mod. G Outer AC Broach Steel 1 ft lng tool 1.5000 sec 1.5000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

- - - 1 Wash Cycles thru machining - - - - - - -

$0.00 Operation G Outer AC Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Operation G Outer AC Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Operation G Outer AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Operation G Outer AC Wash Part 5.0000 sec 5.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Operation G Outer AC Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Operation G Outer AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Material Mod. G Outer AC Paint Part 0.3000 sec 0.3000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Operation G Outer AC Unload Part 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub, 

Spline

$0.00 Operation G Outer AC Align to Base 2.0000 sec 2.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub

$0.00 P.-P. Part G Outer AC G Outer AC Clutch Hub, Pin G Outer AC 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub Clutch Hub, Pin

$0.00 Operation G Outer AC Insert Pins 2.0000 sec 2.0000 sec $0.00 $0.00 3 $0.00

Clutch Hub

$0.00 Material Mod. G Outer AC Swage 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub

Design Profit ®

Page 33 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty Piece Cost 

Rate Score Cost (Total) (Total)

$0.00 Fastening G AC Systems Set In Place 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

$0.00 Part G AC Systems G Bolt, Outer AC Hub G Bolt, Outer AC 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Hub

$0.00 Tool G AC Systems Power Tool 4.0000 sec 4.0000 sec $0.00 $0.00 1 $0.00

$0.00 Fastening G AC Systems Power Screw 4.0000 sec 4.0000 sec $0.00 $0.00 1 $0.00

$0.00 Part G AC Systems G cover, AC Clutch Hub G cover, AC 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

Clutch Hub

$0.00 Fastening G AC Systems Set In Place 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

$0.00 Part G AC Systems G Bolt, AC Clutch Hub Cover G Bolt, AC Clutch 6.0000 sec 6.0000 sec $0.00 $0.00 3 $0.00

Hub Cover

$0.00 Tool G AC Systems 3 Spindle Nut Runner 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

$0.00 Fastening G AC Systems Power Screw 4.0000 sec 4.0000 sec $0.00 $0.00 1 $0.00

$0.00 Operation G AC Systems CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1 $0.00

$0.00 P.-P. Part G AC Systems G Bracket, Stamped, AC G Bracket, 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

electrical Stamped, AC 

electrical

$0.00 Part G AC Systems G Bolt, Bracket, AC Electrical G Bolt, Bracket, 6.0000 sec 6.0000 sec $0.00 $0.00 1 $0.00

AC Electrical

$0.00 Tool G AC Systems Power Tool 4.0000 sec 4.0000 sec $0.00 $0.00 1 $0.00

$0.00 Fastening G AC Systems Power Screw 4.0000 sec 4.0000 sec $0.00 $0.00 1 $0.00

Report Totals Count: ##

899 $0.00

Design Profit ®

Page 34 of #

Copyright 2005© Munro & Associates, Inc.
Assembly Report

G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$0.00 Tool G AC Systems First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

$0.00 Subassembly G AC Systems G AC Pump Asm. G AC Pump Asm. 3.0000 sec 3.0000 sec - $0.00 1

$0.00 Tool G AC Pump Asm. First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

$43.52 Subassembly G AC Pump Asm. G Center Pump Asm. G Center Pump 3.0000 sec 3.0000 sec - $0.00 1

Asm.

Media:

$43.52 Tool G Center Pump First Fixture 4.00 ?? 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm.

$43.52 Subassembly G Center Pump G Rear Pump Housing, Asm. G Rear Pump 4.0000 sec 4.0000 sec 4 - $0.05 1

Asm. Housing, Asm.

Media:

7.00

x $43.52 Tool G Rear Pump First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Asm.

$10.75 P.-P. Part G Rear Pump G Rear Pump Housing, Wash G Rear Pump 4.0000 sec 4.0000 sec 4 - $0.05 1

Housing, Asm. Housing, Wash

Media:

$10.75 Tool G Rear Pump Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec 0 $0.00 $0.00 1

Housing, Wash DRY

Design Profit ®

Page 1 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 P.-P. Part G Rear Pump G Rear Pump Housing, Machined G Rear Pump 3.0000 sec 3.0000 sec 3 - $0.01 1

Housing, Wash Housing, 

Machined

Media:

$41.20 Tool G Rear Pump EC-300-AL Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Machine

Machined

Media:

- - - Pallet Size 300 mm square, 550 Pallet Size 300 mm square, 550 - - - - - -

lb Capacity

x $43.52 P.-P. Part G Rear Pump G Rear Pump Housing-Trimmed G Rear Pump 4.0000 sec 4.0000 sec 4 - $0.05 1

Housing, Housing-Trimmed

Machined #

Media:

- - - Die Cast Trimming - - - - - -

x $43.52 Tool G Rear Pump Trim Press 11.14 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing-Trimmed

Design Profit ®
Page 

2 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $116.73 P.-P. Part G Rear Pump G Rear Pump Housing-Cast G Rear 5.0000 sec 7.1400 sec 7.14 $0.99 $0.09 1

Housing-Trimmed Housing-Cast

Media:

x $116.73 Tool G Rear Pump Die Casting 500 - 1000 ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing-Cast

x $116.73 Part G Rear Pump G Rear Pump Housing, Alum G Rear Pump 0.0000 sec 8.7700 sec $0.00 $0.28 1

Housing-Cast Matl Housing, Alum 

Matl

Media:

- - - Raw Material Req 0.904 lbs - - - - - -

- - - 4 Cavity Mold - - - - - -

- - - Box Size 4.4" L x 5.2" W x 1" H - - - - - -

x $41.20 Operation G Rear Pump Load Part 66.00 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Housing, 

Machined

x $41.20 Operation G Rear Pump Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Housing, 

Machined

- - - Front Face - - - - - -

x $41.20 Material Mod. G Rear Pump Turn End Face 60-100mm 6.0000 sec 6.0000 sec 6 $0.00 $0.07 1

Housing, 

Machined

x $41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

x $41.20 Material Mod. G Rear Pump Turn OD Med 60-100mm 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Housing, 

Machined

Design Profit ®
Page 

3 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

x $41.20 Material Mod. G Rear Pump Cut Groove Large 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

x $41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

x $41.20 Material Mod. G Rear Pump Chamfer OD 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Housing, 

Machined

x $41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

x $41.20 Material Mod. G Rear Pump Spot Face Small 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 5

Housing, 

Machined

x $41.20 Operation G Rear Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 4

Housing, 

Machined

x $41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

x $41.20 Material Mod. G Rear Pump Bore Hole 30-60mm 2.0000 sec 2.0000 sec 2 $0.00 $0.02 5

Housing, 

Machined

x $41.20 Operation G Rear Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 4

Housing, 

Machined

x $41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

x $41.20 Material Mod. G Rear Pump Hone Hole 2 inch depth 3.0000 sec 3.0000 sec 3 $0.00 $0.03 5

Housing, 

Machined

x $41.20 Operation G Rear Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 4

Housing, 

Machined

x $41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

- - - Step multi-tool - 27.00 - - - - -
Design Profit

®

Page 4 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $41.20 Material Mod. G Rear Pump Drill Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 5

Housing, 

Machined

x $41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

x $41.20 Material Mod. G Rear Pump Drill Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 3

Housing, 

Machined

x $41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

x $41.20 Material Mod. G Rear Pump Chamfer Bolt Hole 1.0000 sec 1.0000 sec 1 $0.00 $0.01 3

Housing, 

Machined

x $41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

x $41.20 Material Mod. G Rear Pump Drill Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

x $41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

x $41.20 Material Mod. G Rear Pump Chamfer Bolt Hole 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

x $41.20 Material Mod. G Rear Pump Drill Hole 30 - 60mm 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Housing, 

Machined

- - - Center Bore - 19.50 - - - - -

x $41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

x $41.20 Material Mod. G Rear Pump Bore Hole 30-60mm 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Housing, 

Machined

x $41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

x $41.20 Material Mod. G Rear Pump Spot Face 0.5000 sec 0.5000 sec 0.5 $0.00 $0.01 1

Housing, 

Machined
Design Profit

®

Page 5 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $41.20 Operation G Rear Pump Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

x $41.20 Operation G Rear Pump Part Manipulation 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Housing, 

Machined

x $41.20 Operation G Rear Pump Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Housing, 

Machined

- - - Back Face - 28.00 - - - - -

x $41.20 Material Mod. G Rear Pump Turn OD Med 60-100mm 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Housing, 

Machined

x $41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

x $41.20 Material Mod. G Rear Pump Spot Face 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Housing, 

Machined

x $41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

x $41.20 Material Mod. G Rear Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 3

Housing, 

Machined

x $41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

x $41.20 Material Mod. G Rear Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 2

Housing, 

Machined

x $41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

x $41.20 Material Mod. G Rear Pump Chamfer Bolt Hole 1.0000 sec 1.0000 sec 1 $0.00 $0.01 3

Housing, 

Machined

- - - Dual Angle Chamfer on 5 Bore - 6.00 - - - - -

Holes

x $41.20 Operation G Rear Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined
Design Profit

®

Page 6 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

- - - Combo Tool Dual Chamfer - 9.00 - - - - -

x $41.20 Material Mod. G Rear Pump Chamfer ID 1.0000 sec 1.0000 sec 5 $0.00 $0.01 5

Housing, 

Machined

$41.20 Operation G Rear Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 4

Housing, 

Machined

x $41.20 Operation G Rear Pump Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

x $41.20 Operation G Rear Pump Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Housing, 

Machined

x $10.75 Operation G Rear Pump Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.01 1

Housing, Wash

x $10.75 Operation G Rear Pump Wash Part Medium 5.0000 sec 5.0000 sec 5 $0.00 $0.01 1

Housing, Wash

x $10.75 Operation Operation G Rear Pump G Rear Pump Remove Part Remove Part 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec 2 $0.00 $0.01 1

Housing, Wash

- - - Batch Type Washer - 10.00 - - - - -

- - - 5-10 min cycle time - - - - - -

- - - size 15.75x18.50x25.50 inches x - - - - - -

2

x $0.00 Subassembly G Rear Pump G Bearing, Needle, AC Pump G Bearing, PP 5.0000 sec 5.0000 sec 5 $0.55 $0.06 1

Housing, Asm. Needle, AC 

Pump

Media:

x $43.52 Tool G Rear Pump Press 21.00 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Asm.

Design Profit ®
Page 

7 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $43.52 Fastening G Rear Pump Press Together 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Housing, Asm.

Media:

x $43.52 Operation G Rear Pump Change Tool 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Housing, Asm.

x $43.52 Material Mod. G Rear Pump Swage 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, Asm.

Media:

$43.52 Part G Rear Pump G Rear Pump G Dowel, Small, Rear Housing G Dowel, Small, Rear Housing G Dowel, Small, G Dowel, Small, PP 6.0000 sec 6.0000 sec 6.0000 sec 6.0000 sec 6 $0.00 $0.07 3

Housing, Asm. Rear Housing

Media:

x $43.52 Tool G Rear Pump Hand Tool 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Housing, Asm.

x $43.52 Operation G Rear Pump Press part 3.0000 sec 3.0000 sec 3 $0.00 $0.04 3

Housing, Asm.

Media:

Design Profit ®

Page 8 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $43.52 Operation G Rear Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, Asm.

x $16.39 P.-P. Part G Rear Pump G O-Ring, Housing, AC Pump G O-Ring, 7.0000 sec 7.0000 sec - $0.08 1

Housing, Asm. Housing, AC PP

Pump

Media:

- - - "Injection Molding, Small Size - - - - - -

and/or Low Complexi

- - - 55-150 ton Injection Molding - - - - - -

Machines

x $16.39 Tool G O-Ring, Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, AC ton

Pump

x $16.39 Part G O-Ring, G O-Ring, Housing, AC Pump, G O-Ring, 0.0000 sec 1.2540 sec $0.06 $0.01 1

Housing, AC SBR Mtl Housing, AC 

Pump Pump, SBR Mtl

- - - Raw Material Req 0.008 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 109mm Dia x 3.67mm H - - - - - -

x $43.52 Operation G Rear Pump Set O-ring in Place 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Housing, Asm.

Media:

Design Profit ®
Page 

9 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$0.00 P.-P. Part G Center Pump G Spacer, Shaft, Large G Spacer, Shaft, 6.0000 sec 6.0000 sec $0.11 $0.07 1

Asm. Large

Media:

$43.52 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm.

Media:

$0.00 Subassembly G Center Pump G Thrust Bearing, Shaft G Thrust Bearing, 6.0000 sec 6.0000 sec $0.17 $0.07 1

Asm. Shaft

Media:

$43.52 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm.

Media:

Design Profit ®
Page 10 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$0.00 P.-P. Part G Center Pump G Spacer, Shaft, Small G Spacer, Shaft, 6.0000 sec 6.0000 sec $0.12 $0.07 1

Asm. Small

Media:

$43.52 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm.

Media:

$0.00 Subassembly G Center Pump G Shaft and Swash Plate Asm. G Shaft and 6.0000 sec 6.0000 sec $0.00 $0.07 1

Asm. Swash Plate 

Asm.

Media:

$0.00 Tool G Shaft and First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Swash Plate 

Asm.

$0.00 P.-P. Part G Shaft and G Shaft, AC Pump G Shaft, AC 3.0000 sec 3.0000 sec $0.00 $0.00 1

Swash Plate Pump

Asm.

Media:

Design Profit ®

Page 11 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$0.00 Tool G Shaft, AC Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Pump DRY

$0.00 P.-P. Part G Shaft, AC G Shaft, AC Pump, Wash G Shaft, AC 3.0000 sec 3.0000 sec $0.00 $0.00 1

Pump Pump, Wash

Media:

$0.00 Tool G Shaft, AC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Pump, Wash

$0.00 P.-P. Part G Shaft, AC G Shaft, AC Pump, Trimmed G Shaft, AC 3.0000 sec 3.0000 sec $0.00 $0.00 1

Pump, Wash Pump, Trimmed

Media:

$0.00 Tool G Shaft, AC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Pump, Trimmed

$0.00 Operation G Shaft, AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1

Pump, Wash

$0.00 Operation G Shaft, AC Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1

Pump, Wash

- - - BROACH SPLINE - - - - - -

$0.00 Operation G Shaft, AC Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1

Pump, Wash

$0.00 Operation G Shaft, AC Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 1

Pump, Wash

$0.00 Operation G Shaft, AC Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1

Pump, Wash

$0.00 Operation G Shaft, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1

Pump, Wash

$0.00 Operation G Shaft, AC Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1

Pump, Wash

$0.00 Operation G Shaft, AC Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1

Pump, Wash

Design Profit ®

Page 12 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$0.00 Operation G Shaft, AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1

Pump

$0.00 Operation G Shaft, AC Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.00 1

Pump

$0.00 Operation G Shaft, AC Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1

Pump

- - - Batch Type Washer - - - - - -

- - - 5-10 min cycle time - - - - - -

- - - size 15.75x18.50x25.50 inches x - - - - - -

2

$0.00 P.-P. Part G Shaft and G Swash Plate, AC Pump G Swash Plate, 3.0000 sec 3.0000 sec $0.00 $0.00 1

Swash Plate AC Pump

Asm.

Media:

$0.00 Tool G Swash Plate, G Swash Plate, First Fixture First Fixture 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Pump

$0.00 Operation G Swash Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1

AC Pump

$0.00 Operation G Swash Plate, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1

AC Pump

$0.00 Material Mod. G Swash Plate, Broach Steel 1 ft lng tool 1.5000 sec 1.5000 sec $0.00 $0.00 1

AC Pump

- - - 1 Wash Cycles thru machining - - - - - -

$0.00 Operation G Swash Plate, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1

AC Pump

$0.00 Operation G Swash Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1

AC Pump

$0.00 Operation G Swash Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1

AC Pump

$0.00 Operation G Swash Plate, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.00 1

AC Pump

$0.00 Operation G Swash Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1

AC Pump

Design Profit ®
Page 13 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$0.00 Tool G Shaft and Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Swash Plate 

Asm.

$0.00 Fastening G Shaft and Press Together 3.0000 sec 3.0000 sec $0.00 $0.00 1

Swash Plate 

Asm.

$43.52 Subassembly G Center Pump G Piston Asm. AC Compressor G Piston Asm. 6.0000 sec 6.0000 sec - $0.07 5

Asm. AC Compressor

Media:

$43.52 Tool G Piston Asm. First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 5

AC Compressor

$10.75 P.-P. Part G Piston Asm. G Piston, AC Compressor, G Piston, AC 3.0000 sec 3.0000 sec - $0.04 5

AC Compressor Washed Compressor, 

Washed

Media:

$10.75 Tool G Piston, AC Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 5

Compressor, DRY

Washed

$27.47 P.-P. Part G Piston, AC G Piston, AC Compressor, G Piston, AC 3.0000 sec 3.0000 sec - $0.01 5

Compressor, Machine Compressor, 

Washed Machine

Media:

Design Profit ®

Page 14 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$27.47 Tool G Piston, AC CNC Turning 4 Axis SL-10, Odd 0.0000 sec 0.0000 sec $0.00 $0.00 5

Compressor, Form

Machine

Media:

$43.52 P.-P. Part G Piston, AC G Piston, AC Compressor, G Piston, AC 3.0000 sec 3.0000 sec 3 - $0.02 5

Compressor, Trimmed Compressor, 

Machine Trimmed

Media:

$43.52 Tool G Piston, AC Trim Press 9.16 0.0000 sec 0.0000 sec $0.00 $0.00 5

Compressor, 

Trimmed

$70.80 P.-P. Part G Piston, AC G Piston, AC Compressor, Cast G Piston, AC 5.0000 sec 6.1600 sec 6.16 - $0.07 5

Compressor, Compressor, 

Trimmed Cast

$70.80 Tool G Piston, AC Die Casting 0 - 500 ton 0.0000 sec 0.0000 sec $0.00 $0.00 5

Compressor, 

Cast

$70.80 Part G Piston, AC G Piston, AC Compressor, Alum G Piston, AC 0.0000 sec 3.9700 sec $0.22 $0.08 5

Compressor, Mtl Compressor, 

Cast Alum Mtl3.9700 sec

- - - Raw Material Req 0.196 lbs - - - - - -

- - - 10 Cavity Mold - - - - - -

- - - Box Size 3" L x 1.22" W x 1" H - - - - - -

$27.47 Operation G Piston, AC Load Part 33.00 3.0000 sec 3.0000 sec 3 $0.00 $0.02 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.02 5

Compressor, 

Machine

Design Profit ®

Page 15 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - END FACES - - - - - -

$27.47 Material Mod. G Piston, AC Turn End Face 30-60mm 4.0000 sec 4.0000 sec 4 $0.00 $0.03 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.04 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Part Manipulation 3.0000 sec 3.0000 sec 3 $0.00 $0.02 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.02 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Turn End Face 30-60mm 4.0000 sec 4.0000 sec 4 $0.00 $0.03 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.04 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 5

Compressor, 

Machine

- - - OUTSIDE FEATURES - 15.00 - - - - -

$27.47 Material Mod. G Piston, AC Turn OD 30-60mm 2.0000 sec 2.0000 sec 2 $0.00 $0.02 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Chamfer OD 2.0000 sec 2.0000 sec 2 $0.00 $0.02 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Part Manipulation 3.0000 sec 3.0000 sec 3 $0.00 $0.02 5

Compressor, 

Machine

Design Profit ®
Page 16 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$27.47 Operation G Piston, AC Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.02 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Turn OD 30-60mm 2.0000 sec 2.0000 sec 2 $0.00 $0.02 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Chamfer OD 2.0000 sec 2.0000 sec 2 $0.00 $0.02 5

Compressor, 

Machine

- - - SPECIAL KNURLED ENDS - 16.00 - - - - -

$27.47 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.04 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Knurl OD 2.0000 sec 2.0000 sec 2 $0.00 $0.02 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Part Manipulation 3.0000 sec 3.0000 sec 3 $0.00 $0.02 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.02 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Knurl OD 2.0000 sec 2.0000 sec 2 $0.00 $0.02 5

Compressor, 

Machine

- - - INSIDE FEATURES - - - - - -

- - - SQUARE PADS - 14.00 - - - - -

$27.47 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.04 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Spot Face 2.0000 sec 2.0000 sec 2 $0.00 $0.02 10

Compressor, 

Machine

$27.47 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.04 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Spot Face 2.0000 sec 2.0000 sec 2 $0.00 $0.02 10

Compressor, 

Machine

Design Profit ®
Page 17 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - BALL SOCKETS - 15.50 - - - - -

$27.47 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.04 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Spot Face 2.0000 sec 2.0000 sec 2 $0.00 $0.02 10

Compressor, 

Machine

$27.47 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.04 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Spot Face 0.5000 sec 0.5000 sec 0.5 $0.00 $0.00 10

Compressor, 

Machine

$27.47 Operation G Piston, AC Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.02 5

Compressor, 

Machine

$10.75 Operation G Piston, AC Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.01 5

Compressor, 

Washed

$10.75 Operation G Piston, AC Wash Part Medium 5.0000 sec 5.0000 sec 5 $0.00 $0.01 5

Compressor, 

Washed

$10.75 Operation G Piston, AC Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.01 5

Compressor, 

Washed

- - - Batch Type Washer - 10.00 - - - - -

- - - 5-10 min cycle time - - - - - -

- - - size 15.75x18.50x25.50 inches x - - - - - -

2

$16.39 P.-P. Part G Piston Asm. G Seal, Piston, AC Compressor G Seal, Piston, 6.0000 sec 6.0000 sec - $0.07 10

AC Compressor AC Compressor

Media:

5.00
Design Profit

®

Page 18 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - "Injection Molding, Small Size - - - - - -

and/or Low Complexi

$16.39 Tool G Seal, Piston, Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 10

AC Compressor ton

$16.39 Part G Seal, Piston, G Seal, Piston, AC Compressor, G Seal, Piston, 0.0000 sec 0.6110 sec 0.611 $0.03 $0.00 10

AC Compressor Teflon Mtl AC Compressor, 

Teflon Mtl

- - - Raw Material Req 0.004 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 33.64mm Dia x 5.71mm - - - - - -

H

$43.52 Operation G Piston Asm. Set O-ring in Place 2.0000 sec 2.0000 sec 2 $0.00 $0.02 10

AC Compressor

$43.52 Operation G Piston Asm. Press part 3.0000 sec 3.0000 sec 3 $0.00 $0.04 5

AC Compressor

Media:

$0.00 P.-P. Part G Center Pump G Bearing, Swash Plate to Piston G Bearing, 6.0000 sec 6.0000 sec $0.00 $0.07 10

Asm. Swash Plate to 

Piston

Media:

$43.52 Operation G Center Pump Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.04 10

Asm.

Design Profit ®

Page 19 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$0.00 P.-P. Part G Center Pump G Spacer, Shaft, Large G Spacer, Shaft, 6.0000 sec 6.0000 sec $0.11 $0.07 1

Asm. Large

Media:

$43.52 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm.

Media:

$0.00 Subassembly G Center Pump G Thrust Bearing, Shaft G Thrust Bearing, 6.0000 sec 6.0000 sec $0.17 $0.07 1

Asm. Shaft

Media:

$43.52 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm.

Media:

Design Profit ®
Page 20 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$0.00 P.-P. Part G Center Pump G Spacer, Shaft, Small G Spacer, Shaft, 6.0000 sec 6.0000 sec $0.12 $0.07 1

Asm. Small

Media:

$43.52 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm.

Media:
$0.00 P.-P. Part G Center Pump G Gasket, Pump Housing G Gasket, Pump 6.0000 sec 6.0000 sec - $0.07 1

Asm. Housing

Media:

$0.00 Tool G Gasket, Pump Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing

$0.00 Part G Gasket, Pump G Gasket, Pump Housing, G Gasket, Pump 0.0000 sec 0.7000 sec $0.05 $0.00 1

Housing Material Housing, Material

- - - Blank weight 0.091 lbs - - - - - -

- - - Part Size after stamping (4.62"W - - - - - -

5.2"L 0.0185"H)

Design Profit ®

Page 22 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Next sub-asm NOT ANALYZED - - - - - -

YET 01-22-10

$43.52 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm.

Media:

$43.52 Subassembly G Center Pump G Front Pump Housing, Asm G Front Pump 4.0000 sec 4.0000 sec - $0.05 1

Asm. Housing, Asm

Media:

$43.52 Tool G Front Pump G Front Pump First Fixture First Fixture 7.00 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Asm

$10.75 P.-P. Part G Front Pump G Front Pump Housing, Wash G Front Pump 3.0000 sec 3.0000 sec 3 - $0.04 1

Housing, Asm Housing, Wash

Media:

$10.75 Tool G Front Pump Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Wash DRY

Design Profit ®

Page 23 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 P.-P. Part G Front Pump G Front Pump Housing, G Front Pump 4.0000 sec 4.0000 sec 4 - $0.01 1

Housing, Wash Machined Housing, 

Machined

Media:

$41.20 Tool G Front Pump EC-300-AL Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Machine

Machined

Media:

- - - Pallet Size 300 mm square, 550 - - - - - -

lb Capacity

x $43.52 P.-P. Part G Front Pump G Front Pump Housing, Trimmed G Front Pump 4.0000 sec 4.0000 sec 4 - $0.05 1

Housing, Housing, 

Machined Trimmed

Media:

x $43.52 Tool G Front Pump Trim Press 33.80 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, 

Trimmed

Design Profit ®

Page 24 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $197.05 P.-P. Part G Front Pump G Front Pump Housing, Cast G Front Pump 4.0000 sec 29.8000 sec 29.8 - $0.36 1

Housing, Housing, Raw 

Trimmed Material

Media:

- - - "Aluminum Diecasting, Medium - - - - - -

Size and/or Moderate 

x $197.05 Tool G Front Pump Die Casting 1000-1800 ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Cast

x $197.05 Part G Front Pump G Front Pump Housing, Alum Mtl G Front Pump 0.0000 sec 11.2300 sec $2.05 $0.61 1

Housing, Cast Housing, Alum 

Mtl

Media:

- - - Raw Material Req 1.86375 lbs - - - - - -

from Cost Sheet

- - - 4 Cavity Mold - - - - - -

- - - Box Size 5.85mm L x 5.54mm W - - - - - -

x 2.52mm H

$41.20 Operation G Front Pump Load Part 66.00 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Housing, 

Machined

$41.20 Operation G Front Pump Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Housing, 

Machined

- - - Front Face - - - - - -

$41.20 Material Mod. G Front Pump Turn End Face 60-100mm 6.0000 sec 6.0000 sec 6 $0.00 $0.07 1

Housing, 

Machined

Design Profit ®

Page 25 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Turn OD Med 60-100mm 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Cut Groove Large 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Chamfer OD 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Spot Face Small 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 5

Housing, 

Machined

$41.20 Operation G Front Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 4

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Bore Hole 30-60mm 2.0000 sec 2.0000 sec 2 $0.00 $0.02 5

Housing, 

Machined

$41.20 Operation G Front Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 4

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Hone Hole 2 inch depth 3.0000 sec 3.0000 sec 3 $0.00 $0.03 5

Housing, 

Machined
Design Profit

®

Page 26 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Operation G Front Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 4

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

- - - Step multi-tool - 10.00 - - - - -

$41.20 Material Mod. G Front Pump Drill Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 5

Housing, 

Machined

$41.20 Operation G Front Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 4

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Drill Hole 30 - 60mm 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Chamfer ID 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

- - - Center Bore - 19.50 - - - - -

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Bore Hole 30-60mm 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Spot Face 0.5000 sec 0.5000 sec 0.5 $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Part Manipulation 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Housing, 

Machined

Design Profit ®
Page 27 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Operation G Front Pump Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Housing, 

Machined

- - - Back Face - 52.50 - - - - -

$41.20 Material Mod. G Front Pump Turn End Face 60-100mm 6.0000 sec 6.0000 sec 6 $0.00 $0.07 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Spot Face 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 3

Housing, 

Machined

$41.20 Operation G Front Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 2

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 2

Housing, 

Machined

$41.20 Operation G Front Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 2

Housing, 

Machined

$41.20 Operation G Front Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined
Design Profit

®

Page 28 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Chamfer ID 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Tap Hole 0.5000 sec 0.5000 sec 0.5 $0.00 $0.01 3

Housing, 

Machined

$41.20 Operation G Front Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 2

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

- - - Dual Angle Chamfer on 5 Bore - - - - - -

Holes

- - - Combo Tool Dual Chamfer Combo Tool Dual Chamfer - 2.00 - - - - -

$41.20 Material Mod. G Front Pump Chamfer ID 1.0000 sec 1.0000 sec 1 $0.00 $0.01 5

Housing, 

Machined

$41.20 Operation G Front Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 4

Housing, 

Machined

- - - Interior Angle Hole - 13.00 - - - - -

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Part Manipulation 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Housing, 

Machined

Design Profit ®
Page 29 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Operation G Front Pump Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Housing, 

Machined

- - - Port Face - 45.50 - - - - -

$41.20 Material Mod. G Front Pump Turn End face 1-30mm 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Tap Hole 0.5000 sec 0.5000 sec 0.5 $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Spot Face Small 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Spot Face Small 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined
Design Profit

®

Page 30 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Part Manipulation 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Housing, 

Machined

$41.20 Operation G Front Pump Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Housing, 

Machined

- - - Mounting Holes - 14.00 - - - - -

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Spot Face Small 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 2

Housing, 

Machined

$41.20 Operation G Front Pump Part Manipulation 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Spot Face Small 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 2

Housing, 

Machined

$41.20 Operation G Front Pump Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Housing, 

Machined

$10.75 Operation G Front Pump Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.01 1

Housing, Wash

$10.75 Operation G Front Pump Wash Part Medium 5.0000 sec 5.0000 sec 5 $0.00 $0.01 1

Housing, Wash

$10.75 Operation G Front Pump Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.01 1

Housing, Wash

- - - Batch Type Washer - 10.00 - - - - -

- - - 5-10 min cycle time - - - - - -

Design Profit ®
Page 31 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - size 15.75x18.50x25.50 inches x - - - - - -

2

$0.00 Subassembly G Front Pump G Bearing, Needle, AC Pump G Bearing, PP 5.0000 sec 5.0000 sec 5 $0.55 $0.06 1

Housing, Asm Needle, AC 

Pump

Media:

$43.52 Tool G Front Pump Press 21.00 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Asm

$43.52 Fastening G Front Pump Press Together 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Housing, Asm

Media:

$43.52 Operation G Front Pump Change Tool 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Housing, Asm

$43.52 Material Mod. G Front Pump Swage 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, Asm

Media:

Design Profit ®
Page 32 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$43.52 Part G Front Pump G Dowel, Large Front Housing G Dowel, Large 6.0000 sec 6.0000 sec 6 $0.00 $0.07 2

Housing, Asm Front Housing

Media:

$43.52 Tool G Front Pump Hand Tool 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Housing, Asm

$43.52 Operation G Front Pump Press part 3.0000 sec 3.0000 sec 3 $0.00 $0.04 2

Housing, Asm

Media:

$43.52 Operation G Front Pump CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Housing, Asm

$16.39 P.-P. Part G Front Pump G O-Ring, Housing, AC Pump G O-Ring, 7.0000 sec 7.0000 sec - $0.08 1

Housing, Asm Housing, AC 

Pump PP

Media:

- - - "Injection Molding, Small Size - - - - - -

and/or Low Complexi

- - - 55-150 ton Injection Molding - - - - - -

Machines

$16.39 Tool G O-Ring, Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, AC ton

Pump

Design Profit ®
Page 33 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$16.39 Part G O-Ring, G O-Ring, Housing, AC Pump, G O-Ring, 0.0000 sec 1.2540 sec $0.06 $0.01 1

Housing, AC SBR Mtl Housing, AC 

Pump Pump, SBR Mtl

- - - Raw Material Req 0.008 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 109mm Dia x 3.67mm H - - - - - -

$43.52 Operation G Front Pump Set O-ring in Place 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Housing, Asm

Media:

$43.52 Part G Center Pump G Bolt, Front to Rear Housing G Bolt, Front to 6.0000 sec 6.0000 sec $0.00 $0.07 3

Asm. Rear Housing

Media:

$43.52 Tool G Center Pump 3 Spindle Nut Runner 6.0000 sec 6.0000 sec $0.00 $0.07 1

Asm.

$43.52 Fastening G Center Pump Power Screw 4.0000 sec 4.0000 sec $0.00 $0.05 1

Asm.


G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$20.81 P.-P. Part G AC Pump Asm. G Steel Valve, AC Pump G Steel Valve, 6.0000 sec 6.0000 sec - $0.00 1

AC Pump

Media:

$20.81 Tool G Steel Valve, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Pump

- - - Completed check of analysis - - - - - - -

1/26/10 - do

- - - In-Line Washer - - - - - -

$42.18 P.-P. Part G Steel Valve, G Steel Valve, AC Pump, G Steel Valve, 6.0000 sec 6.0000 sec - $0.03 1

AC Pump Deburred AC Pump, 

Deburr-1

Media:

x $42.18 Tool G Steel Valve, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Pump, 

Deburred

x $42.91 P.-P. Part G Steel Valve, G Steel Valve, AC Pump, G Steel Valve, 6.0000 sec 6.0000 sec 6 - $0.07 1

AC Pump, Stamped AC Pump, 1.70

Deburred stamped

Media:

x $42.91 Tool G Steel Valve, Stamping Press 200-400 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Pump, 

Stamped

Design Profit ®

Page 37 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $42.91 Part G Steel Valve, G Steel Valve, AC Pump, G Steel Valve, 0.0000 sec 1.7000 sec 1.7 $0.03 $0.02 1

AC Pump, Material AC Pump, 

Stamped Material

- - - Blank weight 0.067 lbs - - - - - -

- - - Press Size 200-400 Ton - - - - - -

Progressive

- - - Part Size after stamping (4.28" - - - - - -

Dia, 0.012" Thick)

x $42.18 Operation G Steel Valve, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

AC Pump, 

Deburred

x $42.18 Material Mod. G Steel Valve, Debur/Tumble 14.00 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

AC Pump, 

Deburred

x $42.18 Operation G Steel Valve, Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

AC Pump, 

Deburred

x $20.81 Operation G Steel Valve, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.02 1

AC Pump

x $20.81 Operation G Steel Valve, Wash Part Medium 18.00 5.0000 sec 5.0000 sec 5 $0.00 $0.03 1

AC Pump

x $20.81 Operation G Steel Valve, Unload Part 2.0000 sec 2.0000 sec 2 $0.00 $0.01 1

AC Pump

x $0.00 Operation G AC Pump Asm. Align to Housing 2.0000 sec 2.0000 sec 2 $0.00 $0.00 1

x $20.81 Subassembly G AC Pump Asm. G Valve Plate, Front Cover G Valve Plate, 6.0000 sec 6.0000 sec 6 - $0.00 1

Front Cover

Media:

$20.81 Tool G Valve Plate, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Front Cover

- - - Analysis checked - DO - 1/26/10 - - - - - -

Design Profit ®

Page 38 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$10.75 P.-P. Part G Valve Plate, G Valve Plate, Base, Front G Valve Plate, 4.0000 sec 4.0000 sec - $0.02 1

Front Cover Base, Front

Media:

$10.75 Tool G Valve Plate, Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Base, Front DRY

- - - Analysis checked - DO - 1/26/10 - - - - - -

$31.33 P.-P. Part G Valve Plate, G Valve Plate, Base, Wash, , G Valve Plate, 4.0000 sec 4.0000 sec - $0.01 1

Base, Front Front Base, Wash, 

Front

Media:

$31.33 Tool G Valve Plate, EC-300-ML Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 1

Base, Wash, , Machine

Front

Media:

Design Profit ®

Page 39 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$42.91 P.-P. Part G Valve Plate, G Valve Plate, Trimmed, Front G Valve Plate, 4.0000 sec 4.0000 sec - $0.03 1

Base, Wash, , Trimmed, Front

Front

Media:

$42.91 Tool G Valve Plate, Stamping Press 200-400 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Trimmed, Front

$42.91 Part G Valve Plate, G Steel Valve, Valve Plate Base, G Steel Valve, 0.0000 sec 1.7000 sec $0.30 $0.02 1

Trimmed, Front Front Valve Plate Base, 

Front

Media:

- - - Blank weight 0.552 lbs - - - - - -

- - - Press Size 200-400 Ton - - - - - -

Progressive

- - - Part Size after stamping (4.28" - - - - - -

Dia., 0.088 Thick)

$31.33 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Base, Wash, , 

Front

$31.33 Operation G Valve Plate, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Base, Wash, , 

Front

- - - GRIND OUTER DIAMETER - - - - - -

$31.33 Material Mod. G Valve Plate, Gound OD 1 inch 2.0000 sec 2.0000 sec $0.00 $0.02 1

Base, Wash, , 

Front

- - - GRIND SURFACE FACES - - - - - -

$31.33 Operation G Valve Plate, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

Base, Wash, , 

Front

Design Profit ®

Page 40 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$31.33 Material Mod. G Valve Plate, Ground end faces 5.0000 sec 5.0000 sec $0.00 $0.04 1

Base, Wash, , 

Front

$31.33 Operation G Valve Plate, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Base, Wash, , 

Front

$31.33 Material Mod. G Valve Plate, Ground end faces 5.0000 sec 5.0000 sec $0.00 $0.04 1

Base, Wash, , 

Front

- - - REMOVE PART - - - - - -

$31.33 Operation G Valve Plate, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Base, Wash, , 

Front

$31.33 Operation G Valve Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Base, Wash, , 

Front

$10.75 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Base, Front

$10.75 Operation G Valve Plate, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 1

Base, Front

$10.75 Operation Operation G Valve Plate, G Valve Plate, Remove Part Remove Part 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec $0.00 $0.01 1

Base, Front

- - - Batch Type Washer - - - - - -

- - - 5-10 min cycle time - - - - - -

- - - size 15.75x18.50x25.50 inches x - - - - - -

2

$20.81 Operation G Valve Plate, Align to Base 2.0000 sec 2.0000 sec $0.00 $0.01 1

Front Cover

$10.75 P.-P. Part G Valve Plate, G Valve Plate, Valve G Valve Plate, 4.0000 sec 4.0000 sec - $0.02 1

Front Cover Valve

Media:

x $10.75 Tool G Valve Plate, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Valve

- - - Analysis checked - DO - 1/26/10 - - - - - -

Design Profit ®

Page 41 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$42.18 P.-P. Part G Valve Plate, G Valve Plate, Valve G Valve Plate, 4.0000 sec 4.0000 sec 4 - $0.01 1

Valve Valve, Deburred

Media:

$42.18 Tool G Valve Plate, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Valve

$15.50 P.-P. Part G Valve Plate, G Valve Plate, Valve G Valve Plate, 4.0000 sec 4.0000 sec 4 - $0.05 1

Valve Valve, Stamped

Media:

$15.50 Tool G Valve Plate, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Valve

$15.50 Part G Valve Plate, G Valve Plate, Valve G Valve Plate, 0.60 0.0000 sec 0.6000 sec 0.6 $0.02 $0.00 1

Valve Valve

Media:

- - - Blank weight 0.024 lbs - - - - - -

- - - Press Size 60 Ton Progressive - - - - - -

- - - Part Size after stamping (2.2" Dia - - - - - -

x 0.015" Thk)

$42.18 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Valve

$42.18 Material Mod. G Valve Plate, Debur/Tumble 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Valve

$42.18 Operation G Valve Plate, Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Valve

Design Profit ®

Page 42 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - In-Line Washer - 10 - - - - -

x $10.75 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.01 1

Valve

x $10.75 Operation G Valve Plate, Wash Part Medium 5.0000 sec 5.0000 sec 5 $0.00 $0.01 1

Valve

x $10.75 Operation G Valve Plate, Unload Part 2.0000 sec 2.0000 sec 2 $0.00 $0.01 1

Valve

x $20.81 Operation G Valve Plate, Align to Base 2.0000 sec 2.0000 sec 2 $0.00 $0.01 1

Front Cover

x $15.50 P.-P. Part G Valve Plate, G Valve Plate, Top G Valve Plate, 2.0000 sec 2.0000 sec 2 - $0.01 1

Front Cover Top

Media:

$15.50 Tool G Valve Plate, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Top

- - - Analysis checked - DO - 1/26/10 Analysis checked - DO - 1/26/10 - - - - - -

x $42.18 P.-P. Part G Valve Plate, G Valve Plate, Top, Deburred G Valve Plate, 6.0000 sec 6.0000 sec - $0.03 1

Top Top, Deburred

Media:

x $42.18 Tool G Valve Plate, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Top, Deburred

x $42.18 P.-P. Part G Valve Plate, G Valve Plate, Top, Stamped G Valve Plate, 6.0000 sec 6.0000 sec - $0.07 1

Top, Deburred Top, Stamped

Media:

Design Profit ®

Page 43 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $42.18 Tool G Valve Plate, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Top, Stamped

x $42.18 Part G Valve Plate, G Steel Valve, Top G Steel Valve, 0.0000 sec 0.6000 sec $0.04 $0.01 1

Top, Stamped Top

Media:

- - - Blank weight 0.072 lbs - - - - - -

- - - Part Size after stamping (2.2" - - - - - -

Dia., 0.1 Thick)

x $42.18 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Top, Deburred

x $42.18 Material Mod. G Valve Plate, Debur/Tumble 14.00 3.0000 sec 3.0000 sec $0.00 $0.04 1

Top, Deburred

x $42.18 Operation G Valve Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Top, Deburred

- - - In-Line W In-Line Washer - 16.00 - - - - -

x $15.50 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Top

x $15.50 Operation G Valve Plate, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.02 1

Top

x $15.50 Operation G Valve Plate, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Top

x $20.81 Operation G Valve Plate, Insert Pins 2.0000 sec 2.0000 sec $0.00 $0.01 4

Front Cover

x $20.81 Part G Valve Plate, G Valve Plate, Pin G Valve Plate, 5.0000 sec 5.0000 sec $0.00 $0.03 4

Front Cover Pin

Media:

- - - ALL FOUR PINS SWAGE AT - - - - - -

ONCE

Design Profit ®

Page 44 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$20.81 Material Mod. G Valve Plate, Swage 1.0000 sec 1.0000 sec $0.00 $0.01 1

Front Cover

$0.00 Operation G AC Pump Asm. Align to Housing 2.0000 sec 2.0000 sec $0.00 $0.00 1

x $15.50 P.-P. Part G AC Pump Asm. G Gasket, Front Cover G Gasket, Front 6.0000 sec 6.0000 sec - $0.00 1

Cover

Media:

x $15.50 Tool G Gasket, Front Stamping Press 0-60 Ton stamp 0.7000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover

x $15.50 Part G Gasket, Front G Gasket, Front Cover, Material G Gasket, Front 0.0000 sec 0.7000 sec $0.04 $0.00 1

Cover Cover, Material

- - - Blank weight 0.075 lbs - - - - - -

- - - Part Size after stamping (4.28" - - - - - -

Dia., 0.014Thick)

$0.00 Operation G AC Pump Asm. Align to Housing Assemble/align 8.00 2.0000 sec 2.0000 sec 2 $0.00 $0.00 1

Design Profit ®

Page 45 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$43.52 Subassembly G AC Pump Asm. G Front Cover Asm. G Front Cover 6.0000 sec 6.0000 sec 6 - $0.00 1

Asm.

Media:

$43.52 Tool G Front Cover First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm.

$10.75 P.-P. Part G Front Cover G Front Cover, Wash G Front Cover, 4.0000 sec 4.0000 sec - $0.05 1

Asm. Wash

Media:

$10.75 Tool G Front Cover, G Front Cover, Washer Duo 400 W sher Duo 400 Wash Rinse & ash Rinse & 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 1

Wash DRY

x $41.20 P.-P. Part G Front Cover, G Front Cover, Machined G Front Cover, 3.0000 sec 3.0000 sec - $0.01 1

Wash Machined

Media:

- - - Machining for Trimmed Die Cast - - - - - -

- - - "CNC Mach, Auto Sml Size - - - - - -

and/or Low Complexity"

Design Profit ®
Page 46 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $41.20 Tool G Front Cover, EC-300-AL Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 1

Machined Machine

Media:

- - - Pallet Size 300 mm square, 550 - - - - - -

lb Capacity

x $43.52 P.-P. Part G Front Cover, G Front Cover-Trimmed G Front 11.13 4.0000 sec 4.0000 sec 4 - $0.05 1

Machined Cover-Trimmed

Media:

- - - Die Cast Part Trimming Die Cast Part Trimming - - - - - -

$43.52 Tool G Front Trim Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover-Trimmed

x $116.73 P.-P. Part G Front G Front Cover Asm, Casting G Front Cover 12.19 0.0000 sec 7.1300 sec 7.13 - $0.09 1

Cover-Trimmed Asm, Casting

Media:

- - - "Aluminum Diecasting, Medium - - - - - -

Size and/or Moderate 

$116.73 Tool G Front Cover Die Casting 500 - 1000 ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Casting

Design Profit ®

Page 47 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$116.73 Part G Front Cover G Front Cover-Alum Mtl G Front 0.0000 sec 12.1900 sec 12.19 $0.86 $0.40 1

Asm, Casting Cover-Alum Mtl

Media:

- - - Raw Material Req 0.784 lbs - - - - - -

- - - 4 Cavity Mold - - - - - -

- - - Box Size 4.5" L x 5.1" W x 3" H - - - - - -

$41.20 Operation G Front Cover, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Machined

$41.20 Operation G Front Cover, Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Machined

- - - Front Face - 30.00 - - - - -

$41.20 Material Mod. G Front Cover, Turn End face 1-30mm 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Machined

$41.20 Operation Operation G Front Cover, G Front Cover, Auto Tool Change Auto Tool Change 5.0000 sec 5.0000 sec 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Turn OD 30-60mm 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Cut Groove sml 2.0000 sec 2.0000 sec 2 $0.00 $0.02 2

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Turn End face 1-30mm 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Machined

$41.20 Operation G Front Cover, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Chamfer OD sml 1.0000 sec 1.0000 sec 1 $0.00 $0.01 2

Machined

- - - Locationg feature - 17.00 - - - - -

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Machined

Design Profit ®
Page 48 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Material Mod. G Front Cover, Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Bore Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Machined

- - - Inner groove - 22.50 - - - - -

$41.20 Material Mod. G Front Cover, Cut Groove sml 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Chamfer OD sml 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Drill Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 5

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Spot Face 0.5000 sec 0.5000 sec 0.5 $0.00 $0.01 5

Machined

$41.20 Operation G Front Cover, Part Manipulation 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Machined

- - - Inside of Outer Lip - 10.00 - - - - -

$41.20 Material Mod. G Front Cover, Turn OD Med 60-100mm 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Machined

$41.20 Operation G Front Cover, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Machined

$41.20 Material Mod. G Front Cover, Turn End Face 60-100mm 6.0000 sec 6.0000 sec 6 $0.00 $0.07 1

Machined

- - - Inner Bore - 27.00 - - - - -

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Spot Face 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Machined

Design Profit ®
Page 49 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Chamfer ID 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Machined

$41.20 Material Mod. G Front Cover, Chamfer OD sml 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Bore Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Machined

- - - Angled Ports - 9.00 - - - - -

$41.20 Operation G Front Cover, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Drill Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Machined

$41.20 Material Mod. G Front Cover, Drill Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Machined

- - - Tab - 14.00 - - - - -

$41.20 Operation G Front Cover, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Drill and Tap Hole 1-30mm 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Machined

$41.20 Operation G Front Cover, Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Machined

$10.75 Operation G Front Cover, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.01 1

Wash

$10.75 Operation G Front Cover, Wash Part Medium 5.0000 sec 5.0000 sec 5 $0.00 $0.01 1

Wash

$10.75 Operation G Front Cover, Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.01 1

Wash

- - - Batch Type Washer - 10.00 - - - - -

Design Profit ®
Page 50 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - 5-10 min cycle time - - - - - -

- - - size 15.75x18.50x25.50 inches x - - - - - -

2

$0.00 Subassembly G Front Cover G Seal, Front Cover G Seal, Front 6.0000 sec 6.0000 sec 6 $0.00 $0.07 1

Asm. Cover 36.00

Media:

$43.52 Operation G Front Cover Part Manipulation 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Asm.

$43.52 Tool G Front Cover Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm.

$43.52 Fastening G Front Cover Press Together 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Asm.

$43.52 Part G Front Cover G Snap-ring, Seal Front Cover G Snap-ring, Seal 6.0000 sec 6.0000 sec 6 $0.00 $0.07 1

Asm. Front Cover

Media:

$43.52 Operation G Front Cover CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Asm.

$43.52 Tool G Front Cover Special Tool 6.0000 sec 6.0000 sec 6 $0.00 $0.07 1

Asm.

$43.52 Fastening G Front Cover Position Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Asm.

Media:

Design Profit ®
Page 51 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$43.52 Operation G Front Cover CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Asm.

$43.52 Part G Front Cover G Dust Seal, Cloth, Front Cover G Dust Seal, 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Asm. Cloth, Front 

Cover

Media:

$43.52 Operation G Front Cover Part Manipulation 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Asm.

Media:

$0.00 Operation G AC Pump Asm. Press part 3.0000 sec 3.0000 sec 3 $0.00 $0.00 1

$0.00 Operation G AC Pump Asm. Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 1

$20.81 P.-P. Part G AC Pump Asm. G Steel Valve, AC Pump G Steel Valve, 6.0000 sec 6.0000 sec - $0.00 1

AC Pump

Media:

$20.81 Tool G Steel Valve, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Pump

- - - Completed check of analysis - - - - - - -

1/26/10 - do

- - - In-Line Washer - - - - - -

Design Profit ®

Page 52 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$42.18 P.-P. Part G Steel Valve, G Steel Valve, AC Pump, G Steel Valve, 6.0000 sec 6.0000 sec - $0.03 1

AC Pump Deburred AC Pump, 

Deburr-1

Media:

$42.18 Tool G Steel Valve, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Pump, 

Deburred

$42.91 P.-P. Part G Steel Valve, G Steel Valve, AC Pump, G Steel Valve, 6.0000 sec 6.0000 sec - $0.07 1

AC Pump, Stamped AC Pump, 

Deburred stamped

Media:

$42.91 Tool G Steel Valve, Stamping Press 200-400 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Pump, 

Stamped

$42.91 Part G Steel Valve, G Steel Valve, AC Pump, G Steel Valve, 0.0000 sec 1.7000 sec $0.04 $0.02 1

AC Pump, Material AC Pump, 

Stamped Material

- - - Blank weight 0.067 lbs - - - - - -

- - - Press Size 200-400 Ton - - - - - -

Progressive

- - - Part Size after stamping (4.28" - - - - - -

Dia, 0.012" Thick)

$42.18 Operation G Steel Valve, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

AC Pump, 

Deburred

$42.18 Material Mod. G Steel Valve, Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.04 1

AC Pump, 

Deburred

Design Profit ®

Page 53 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$42.18 Operation G Steel Valve, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

AC Pump, 

Deburred

$20.81 Operation G Steel Valve, Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 1

AC Pump

$20.81 Operation G Steel Valve, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.03 1

AC Pump

$20.81 Operation G Steel Valve, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

AC Pump

$0.00 Operation G AC Pump Asm. Align to Housing 2.0000 sec 2.0000 sec $0.00 $0.00 1

$20.81 Subassembly G AC Pump Asm. G Valve Plate, Rear Cover G Valve Plate, 6.0000 sec 6.0000 sec - $0.00 1

Rear Cover

Media:

$20.81 Tool G Valve Plate, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Rear Cover

Design Profit ®

Page 54 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$10.75 P.-P. Part G Valve Plate, G Valve Plate, Base, Rear G Valve Plate, 4.0000 sec 4.0000 sec - $0.02 1

Rear Cover Base, Rear

Media:

$10.75 Tool G Valve Plate, Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Base, Rear DRY

$31.33 P.-P. Part G Valve Plate, G Valve Plate, Base, Wash, Rear G Valve Plate, 4.0000 sec 4.0000 sec - $0.01 1

Base, Rear Base, Wash, 

Rear

Media:

$31.33 Tool G Valve Plate, EC-300-ML Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 1

Base, Wash, Machine

Rear

Media:

$42.91 P.-P. Part G Valve Plate, G Valve Plate, Base, Trimmed G Valve Plate, 4.0000 sec 4.0000 sec - $0.03 1

Base, Wash, Rear Base, Trimmed, 

Rear Rear

Media:

Design Profit ®

Page 55 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$42.91 Tool G Valve Plate, Stamping Press 200-400 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Base, Trimmed 

Rear

$42.91 Part G Valve Plate, G Steel Valve, Valve Plate Base, G Steel Valve, 0.0000 sec 1.7000 sec $0.30 $0.02 1

Base, Trimmed Rear Valve Plate Base, 

Rear Rear 27.00

- - - Blank weight 0.552 lbs - - - - - -

- - - Press Size 200-400 Ton - - - - - -

Progressive

- - - Part Size after stamping (4.28" - - - - - -

Dia., 0.088 Thick)

$31.33 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Base, Wash, 

Rear

$31.33 Operation G Valve Plate, Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Base, Wash, 

Rear

- - - GRIND OUTER DIAMETER - - - - - -

$31.33 Material Mod. G Valve Plate, Gound OD 1 inch 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Base, Wash, 

Rear

- - - GRIND SURFACE FACES - - - - - -

$31.33 Operation G Valve Plate, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.04 1

Base, Wash, 

Rear

$31.33 Material Mod. G Valve Plate, Ground end faces 5.0000 sec 5.0000 sec 5 $0.00 $0.04 1

Base, Wash, 

Rear

$31.33 Operation G Valve Plate, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Base, Wash, 

Rear

$31.33 Material Mod. G Valve Plate, Ground end faces 5.0000 sec 5.0000 sec 5 $0.00 $0.04 1

Base, Wash, 

Rear

- - - REMOVE PART - - - - - -

$31.33 Operation G Valve Plate, Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Base, Wash, 

Rear

$31.33 Operation G Valve Plate, Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Base, Wash, 

Rear

Design Profit ®
Page 56 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $10.75 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.01 1

Base, Rear

x $10.75 Operation G Valve Plate, Wash Part Medium 5.0000 sec 5.0000 sec 5 $0.00 $0.01 1

Base, Rear

x $10.75 Operation G Valve Plate, Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.01 1

Base, Rear

- - - Batch Type Washer - 10.00 - - - - -

- - - 5-10 min cycle time - - - - - -

- - - size 15.75x18.50x25.50 inches x - - - - - -

2

$20.81 Operation G Valve Plate, Align to Base 2.0000 sec 2.0000 sec $0.00 $0.01 1

Rear Cover

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$10.75 P.-P. Part G Valve Plate, G Valve Plate, Valve G Valve Plate, 4.0000 sec 4.0000 sec - $0.02 1

Rear Cover Valve

Media:

$10.75 Tool G Valve Plate, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Valve

- - - Analysis checked - DO - 1/26/10 - - - - - -

Design Profit ®

Page 57 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$42.18 P.-P. Part G Valve Plate, G Valve Plate, Valve G Valve Plate, 4.0000 sec 4.0000 sec - $0.01 1

Valve Valve, Deburred

Media:

$42.18 Tool G Valve Plate, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Valve

$15.50 P.-P. Part G Valve Plate, G Valve Plate, Valve G Valve Plate, 4.0000 sec 4.0000 sec - $0.05 1

Valve Valve, Stamped

Media:

x $15.50 Tool G Valve Plate, Stamping Press 0-60 Ton 0.60 0.0000 sec 0.0000 sec $0.00 $0.00 1

Valve

$15.50 Part G Valve Plate, G Valve Plate, Valve G Valve Plate, 0.0000 sec 0.6000 sec $0.02 $0.00 1

Valve Valve

Media:

- - - Blank weight 0.024 lbs - - - - - -

- - - Press Size 60 Ton Progressive - - - - - -

- - - Part Size after stamping (2.2" Dia - - - - - -

x 0.015" Thk)

$42.18 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Valve

$42.18 Material Mod. G Valve Plate, Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.04 1

Valve

$42.18 Operation G Valve Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Valve

Design Profit ®

Page 58 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - In-Line Washer - 12.00 - - - - -

$10.75 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Valve

$10.75 Operation G Valve Plate, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 1

Valve

$10.75 Operation G Valve Plate, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Valve

$20.81 Operation G Valve Plate, Align to Base 2.0000 sec 2.0000 sec $0.00 $0.01 1

Rear Cover

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

x $15.50 P.-P. Part G Valve Plate, G Valve Plate, Top G Valve Plate, 2.0000 sec 2.0000 sec - $0.01 1

Rear Cover Top

Media:

x $15.50 Tool G Valve Plate, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Top

- - - Analysis checked - DO - 1/26/10 - - - - - -

x $42.18 P.-P. Part G Valve Plate, G Valve Plate, Top, Deburred G Valve Plate, 14.00 6.0000 sec 6.0000 sec - $0.03 1

Top Top, Deburred

Media:

x $42.18 Tool G Valve Plate, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Top, Deburred

Design Profit ®

Page 59 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $42.18 P.-P. Part G Valve Plate, G Valve Plate, Top, Stamped G Valve Plate, 6.0000 sec 6.0000 sec - $0.07 1

Top, Deburred Top, Stamped

Media:

x $42.18 Tool G Valve Plate, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Top, Stamped

x $42.18 Part G Valve Plate, G Steel Valve, Top G Steel Valve, 0.0000 sec 0.6000 sec $0.04 $0.01 1

Top, Stamped Top

Media:

- - - Blank weight 0.072 lbs - - - - - -

- - - Part Size after stamping (2.2" Part Size after stamping (2.2" - - - - - -

Dia., 0.1 Thick)

x $42.18 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Top, Deburred

x $42.18 Material Mod. G Valve Plate, Debur/Tumble 16.00 3.0000 sec 3.0000 sec $0.00 $0.04 1

Top, Deburred

x $42.18 Operation G Valve Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Top, Deburred

- - - In-Line Washer - 14.00 - - - - -

x $15.50 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Top

x $15.50 Operation G Valve Plate, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.02 1

Top

x $15.50 Operation G Valve Plate, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Top

$20.81 Operation G Valve Plate, Insert Pins 2.0000 sec 2.0000 sec $0.00 $0.01 4

Rear Cover

Design Profit ®

Page 60 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$20.81 Part G Valve Plate, G Valve Plate, Pin G Valve Plate, 2.0000 sec 2.0000 sec $0.00 $0.01 4

Rear Cover Pin

Media:

- - - ALL FOUR PINS SWAGE AT - - - - - -

ONCE

$20.81 Material Mod. G Valve Plate, Swage 1.0000 sec 1.0000 sec $0.00 $0.01 1

Rear Cover

$0.00 Operation G AC Pump Asm. Align to Housing 2.0000 sec 2.0000 sec $0.00 $0.00 1

$0.00 P.-P. Part G AC Pump Asm. G Gasket, Rear Cover G Gasket, Rear 0.70 6.0000 sec 6.0000 sec - $0.00 1

Cover

Media:

$0.00 Tool G Gasket, Rear Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover

$0.00 Part G Gasket, Rear G Gasket, Rear Cover, Material G Gasket, Rear 0.0000 sec 0.7000 sec $0.04 $0.00 1

Cover Cover, Material

- - - Blank weight 0.08 lbs - - - - - -

- - - Part Size after stamping (4.28" - - - - - -

Dia., 0.015Thick)

$0.00 Operation G AC Pump Asm. Align to Housing 2.0000 sec 2.0000 sec $0.00 $0.00 1

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 61 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$43.52 Subassembly G AC Pump Asm. G Rear Cover Asm G Rear Cover 6.0000 sec 6.0000 sec - $0.00 1

Asm

Media:

$43.52 Tool G Rear Cover First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm

$10.75 P.-P. Part G Rear Cover G Rear Cover, Washed G Rear Cover, 3.0000 sec 3.0000 sec - $0.04 1

Asm Washed

Media:

$10.75 Tool G Rear Cover, Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Washed DRY

$41.20 P.-P. Part G Rear Cover, G Rear Cover, Mach G Rear Cover, 4.0000 sec 4.0000 sec - $0.01 1

Washed Mach

Media:

$41.20 Tool G Rear Cover, EC-300-AL Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 1

Mach Machine

Media:

Design Profit ®

Page 62 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Pallet Size 300 mm square, 550 - - - - - -

lb Capacity

$43.52 P.-P. Part G Rear Cover, G Rear Cover, Trimmed G Rear Cover, 3.0000 sec 3.0000 sec 3 - $0.03 1

Mach Trimmed10.14

Media:

- - - Die Cast Part Trimming - - - - - -

$43.52 Tool G Rear Cover, Trim Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Trimmed

$70.80 P.-P. Part G Rear Cover, G Rear Cover, Casting G Rear Cover, 6.0000 sec 7.1400 sec 7.14 - $0.09 1

Trimmed Casting

Media:

- - - "Aluminum Diecasting, Medium - - - - - -

Size and/or Moderate 

$70.80 Tool G Rear Cover, Die Casting 500 - 1000 ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Casting

$70.80 Part G Rear Cover, G Rear Cover, Alum Mtl G Rear Cover, 0.0000 sec 8.2800 sec $0.97 $0.16 1

Casting Alum Mtl

Media:

- - - Raw Material Req 0.884 lbs - - - - - -

- - - 4 Cavity Mold - - - - - -

- - - Box Size 4.5" L x 5.1" W x 1.4" H - - - - - -

Design Profit ®

Page 63 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Operation G Rear Cover, Load Part 56.00 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Mach

$41.20 Operation G Rear Cover, Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Mach

- - - Back Face - - - - - -

$41.20 Material Mod. G Rear Cover, Mill Flat Med 4.0000 sec 4.0000 sec 4 $0.00 $0.05 1

Mach

$41.20 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Mach

$41.20 Material Mod. G Rear Cover, Turn I/D Med 60-100 mm 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Mach

$41.20 Operation G Rear Cover, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Mach

$41.20 Material Mod. G Rear Cover, Spot Face Small 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Mach

$41.20 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Mach

$41.20 Material Mod. G Rear Cover, Chamfer ID Lrg 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Mach

$41.20 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Mach

$41.20 Material Mod. G Rear Cover, Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 2

Mach

$41.20 Operation G Rear Cover, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Mach

$41.20 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Mach

$41.20 Material Mod. G Rear Cover, Tap Hole 2.0000 sec 2.0000 sec 2 $0.00 $0.02 2

Mach

$41.20 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Mach

$41.20 Material Mod. G Rear Cover, Drill and Tap Hole 1-30mm 5.0000 sec 5.0000 sec 5 $0.00 $0.06 3

Mach

$41.20 Operation G Rear Cover, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 2

Mach

$41.20 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Mach

- - - CENTER BORE - 18.00 - - - - -

$41.20 Material Mod. G Rear Cover, Drill and Tap Hole 1-30mm 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Mach

Design Profit ®
Page 64 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Mach

$41.20 Material Mod. G Rear Cover, Chamfer ID 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Mach

$41.20 Operation G Rear Cover, Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Mach

$41.20 Operation G Rear Cover, Part Manipulation 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Mach

$41.20 Operation G Rear Cover, Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Mach

- - - FRONT SIDE - 3.00 - - - - -

$41.20 Material Mod. G Rear Cover, Spot Face 2.0000 sec 2.0000 sec 2 $0.00 $0.02 3

Mach

$41.20 Operation G Rear Cover, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 3

Mach

- - - CENTER BORE - 10.00 - - - - -

$41.20 Material Mod. G Rear Cover, Spot Face 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Mach

$41.20 Material Mod. G Rear Cover, Counter Bore Hole Small 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Mach

$41.20 Operation G Rear Cover, Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Mach

$41.20 Operation G Rear Cover, Part Manipulation 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Mach

$41.20 Operation G Rear Cover, Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Mach

- - - SIDE MOUNTING HOLES - 20.00 - - - - -

$41.20 Material Mod. G Rear Cover, Bore Hole 60-100mm 3.0000 sec 3.0000 sec 3 $0.00 $0.03 2

Mach

$41.20 Operation G Rear Cover, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Mach

$41.20 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Mach

$41.20 Material Mod. G Rear Cover, Spot Face Small 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 2

Mach

$41.20 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.06 1

Mach

$41.20 Material Mod. G Rear Cover, Chamfer ID 1.0000 sec 1.0000 sec 1 $0.00 $0.01 2

Mach

$41.20 Operation G Rear Cover, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Mach

Design Profit ®
Page 65 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Operation G Rear Cover, Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Mach

$41.20 Operation G Rear Cover, Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Mach

$10.75 Operation G Rear Cover, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.01 1

Washed

$10.75 Operation G Rear Cover, Wash Part Medium 5.0000 sec 5.0000 sec 5 $0.00 $0.01 1

Washed

$10.75 Operation G Rear Cover, Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.01 1

Washed

- - - Batch Type Washer - 10.00 - - - - -

- - - 5-10 min cycle time - - - - - -

- - - size 15.75x18.50x25.50 inches x - - - - - -

2

$43.52 Part G Rear Cover G O-ring, Plug, Rear Cover G O-ring, Plug, 20.00 4.0000 sec 4.0000 sec 4 $0.00 $0.05 1

Asm Rear Cover

Media:

$43.52 Operation G Rear Cover Set O-ring in Place 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Asm

$0.00 Subassembly G Rear Cover G Plug Asm. , Rear Cover G Plug Asm. , 6.0000 sec 6.0000 sec 6 $0.00 $0.07 1

Asm Rear Cover

Media:

$43.52 Tool G Rear Cover Power Tool 4.0000 sec 4.0000 sec 4 $0.00 $0.05 1

Asm

Design Profit ®
Page 66 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$43.52 Fastening G Rear Cover Power Screw 4.0000 sec 4.0000 sec 4 $0.00 $0.05 1

Asm

Media:

$0.00 Operation G AC Pump Asm. Press part 3.0000 sec 3.0000 sec $0.00 $0.00 1

$0.00 Operation G AC Pump Asm. Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 1

$0.00 Part G AC Pump Asm. G Bolt, Front Cover to Rear G Bolt, Front 6.0000 sec 6.0000 sec $0.00 $0.00 5

Cover to Rear

Media:

$0.00 Tool G AC Pump Asm. G AC Pump Asm. 5 Spindle Nut Runner 5 Spindle Nut Runner 6.0000 sec 6.0000 sec 6.0000 sec 6.0000 sec $0.00 $0.00 1

$0.00 Fastening G AC Pump Asm. Power Screw 4.0000 sec 4.0000 sec $0.00 $0.00 1

$0.00 Subassembly G AC Systems G Magnet Asm., AC Clutch G Magnet Asm., 6.0000 sec 6.0000 sec $0.00 $0.00 1

AC Clutch

Media:

$0.00 Part G AC Systems G Snap-ring, AC Magnet G Snap-ring, AC 6.0000 sec 6.0000 sec $0.08 $0.00 1

Magnet

Media:

Design Profit ®

Page 67 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$0.00 Operation G AC Systems CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1

$0.00 Tool G AC Systems Special Tool 6.0000 sec 6.0000 sec $0.00 $0.00 1

$0.00 Fastening G AC Systems Position Part 1.0000 sec 1.0000 sec $0.00 $0.00 1

Media:

$0.00 Operation G AC Systems CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1

$0.00 Subassembly G AC Systems G Clutch Pully Asm G Clutch Pully 6.0000 sec 6.0000 sec - $0.00 1

Asm

Media:

$0.00 Tool G Clutch Pully First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm

Design Profit ®

Page 70 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$0.00 P.-P. Part G Clutch Pully G Clutch Pulley G Clutch Pulley 3.0000 sec 3.0000 sec $0.00 $0.00 1

Asm

Media:

- - - PRE PAINTING MACHINING - - - - - -

$0.00 Tool G Clutch Pulley First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

$0.00 P.-P. Part G Clutch Pulley G Clutch Pulley, Machined Final G Clutch Pulley, 3.0000 sec 3.0000 sec $0.00 $0.00 1

Machined Final

Media:

$0.00 Tool G Clutch Pulley, G Clutch Pulley, First Fixture First Fixture 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 1

Machined Final

$0.00 P.-P. Part G Clutch Pulley, G Clutch Pulley, Paint G Clutch Pulley, 3.0000 sec 3.0000 sec $0.00 $0.00 1

Machined Final Paint

Media:

- - - PRE PAINTING MACHINING - - - - - -

$0.00 Tool G Clutch Pulley, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Paint

Design Profit ®

Page 71 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$0.00 P.-P. Part G Clutch Pulley, G Clutch Pulley, Machined G Clutch Pulley, 3.0000 sec 3.0000 sec $0.00 $0.00 1

Paint Machined

Media:

$0.00 Tool G Clutch Pulley, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Machined

$0.00 Operation G Clutch Pulley, Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1

Paint

$0.00 Operation G Clutch Pulley, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1

Paint

- - - FRONT FACE - - - - - -

$0.00 Material Mod. G Clutch Pulley, Turn End Face 60-100mm 6.0000 sec 6.0000 sec $0.00 $0.00 1

Paint

$0.00 Operation G Clutch Pulley, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1

Paint

- - - OUTER DIAMETER OUTER DIAMETER - - - - - -

$0.00 Material Mod. G Clutch Pulley, Turn OD Med 60-100mm 3.0000 sec 3.0000 sec $0.00 $0.00 1

Paint

$0.00 Operation G Clutch Pulley, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1

Paint

- - - CUT BELT GROVES - - - - - -

$0.00 Material Mod. G Clutch Pulley, Turn OD Contoured surface fins 5.0000 sec 5.0000 sec $0.00 $0.00 1

Paint

$0.00 Operation G Clutch Pulley, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1

Paint

- - - INSIDE POCKET BORE - - - - - -

$0.00 Material Mod. G Clutch Pulley, Bore Hole 100-150mm dia 4.0000 sec 4.0000 sec $0.00 $0.00 1

Paint

$0.00 Operation G Clutch Pulley, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1

Paint

$0.00 Material Mod. G Clutch Pulley, Bore Hole 60-100mm 3.0000 sec 3.0000 sec $0.00 $0.00 1

Paint

$0.00 Operation G Clutch Pulley, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1

Paint

$0.00 Material Mod. G Clutch Pulley, Turn End Face 60-100mm 6.0000 sec 6.0000 sec $0.00 $0.00 1

Paint

Design Profit ®
Page 72 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$0.00 Operation G Clutch Pulley, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1

Paint

- - - SHAFT HOLE - - - - - -

$0.00 Material Mod. G Clutch Pulley, Drill Hole 30 - 60mm 2.0000 sec 2.0000 sec $0.00 $0.00 1

Paint

$0.00 Operation G Clutch Pulley, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1

Paint

$0.00 Material Mod. G Clutch Pulley, Bore Hole 60-100mm 3.0000 sec 3.0000 sec $0.00 $0.00 1

Paint

- - - SLOTS - - - - - -

$0.00 Operation G Clutch Pulley, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1

Paint

$0.00 Material Mod. G Clutch Pulley, End Mill Slot cut 1.0000 sec 1.0000 sec $0.00 $0.00 4

Paint

$0.00 Operation G Clutch Pulley, CDI 1.0000 sec 1.0000 sec $0.00 $0.00 3

Paint

$0.00 Material Mod. G Clutch Pulley, End Mill Slot cut 1.0000 sec 1.0000 sec $0.00 $0.00 5

Paint

$0.00 Operation G Clutch Pulley, CDI 1.0000 sec 1.0000 sec $0.00 $0.00 4

Paint

$0.00 Operation G Clutch Pulley, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1

Paint

$0.00 Operation G Clutch Pulley, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1

Paint

$0.00 Operation G Clutch Pulley, Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1

Machined Final

$0.00 Material Mod. G Clutch Pulley, Paint Part 1.6000 sec 1.6000 sec $0.00 $0.00 1

Machined Final

$0.00 Operation G Clutch Pulley, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.00 1

Machined Final

$0.00 Operation G Clutch Pulley Load Part 3.0000 sec 3.0000 sec $0.00 $0.00 1

$0.00 Operation G Clutch Pulley Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.00 1

- - - FRONT FACE - - - - - -

$0.00 Material Mod. G Clutch Pulley Turn End Face 60-100mm 6.0000 sec 6.0000 sec $0.00 $0.00 1

$0.00 Operation G Clutch Pulley Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.00 1

- - - SHAFT HOLE - - - - - -

$0.00 Material Mod. G Clutch Pulley Hone Hole 2 inch depth 3.0000 sec 3.0000 sec $0.00 $0.00 1

$0.00 Operation G Clutch Pulley Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.00 1

$0.00 Operation G Clutch Pulley Remove Part 2.0000 sec 2.0000 sec $0.00 $0.00 1

Design Profit ®
Page 73 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$0.00 Part G Clutch Pully G Clutch Pully, Friction Material G Clutch Pully, 5.0000 sec 5.0000 sec $0.00 $0.00 1

Asm Friction Material

Media:

$0.00 Tool G Clutch Pully Glue Bottle 3.0000 sec 3.0000 sec $0.00 $0.00 1

Asm

$0.00 Fastening G Clutch Pully Glue in Place 2.0000 sec 2.0000 sec $0.00 $0.00 1

Asm

Media:

$0.00 Operation G Clutch Pully Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.00 1

Asm

$0.00 Subassembly G Clutch Pully G Clutch Pulley, Bearing G Clutch Pulley, 6.0000 sec 6.0000 sec $1.51 $0.00 1

Asm Bearing

Media:

$0.00 Tool G Clutch Pully Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm

Design Profit ®

Page 74 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$0.00 Fastening G Clutch Pully Press Together 3.0000 sec 3.0000 sec $0.00 $0.00 1

Asm

Media:

$0.00 Tool G Clutch Pully Stamping Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm

$0.00 Operation G Clutch Pully Change Tool 2.0000 sec 2.0000 sec $0.00 $0.00 1

Asm

$0.00 Material Mod. G Clutch Pully Swage 1.0000 sec 1.0000 sec $0.00 $0.00 1

Asm

Media:

$0.00 Operation G AC Systems CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1

$0.00 Part G AC Systems G Snap-ring, AC Hub G Snap-ring, AC 6.0000 sec 6.0000 sec $0.08 $0.00 1

Hub

Media:

$0.00 Tool G AC Systems Special Tool 6.0000 sec 6.0000 sec $0.00 $0.00 1

Design Profit ®

Page 75 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$0.00 Fastening G AC Systems Position Part 1.0000 sec 1.0000 sec $0.00 $0.00 1

Media:

$0.00 Operation G AC Systems CDI 1.0000 sec 1.0000 sec $0.00 $0.00 1

- - - ** DWarner ** Complete to End - - - - - -

$0.00 Part G AC Systems G Shim, Clutch Hub G Shim, Clutch 6.0000 sec 6.0000 sec $0.00 $0.00 2

Hub

Media:

$0.00 Fastening G AC Systems Set In Place 1.0000 sec 1.0000 sec $0.00 $0.00 2

Media:
$0.00 Subassembly G AC Systems G Clutch Hub Asm G Clutch Hub 6.0000 sec 6.0000 sec - $0.00 1

Asm

Media:

$0.00 Tool G Clutch Hub First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm

$0.00 Part G Clutch Hub G Clutch Hub, Rivet Pin, M5 G Clutch Hub, 3.0000 sec 3.0000 sec $0.00 $0.00 3

Asm Rivet Pin, M5

Media:

Design Profit ®

Page 77 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$42.18 P.-P. Part G Clutch Hub G Clutch Hub, Isolator, Painted G Clutch Hub, 6.0000 sec 6.0000 sec - $0.00 1

Asm Asm Isolator, Painted 

Asm

Media:

$42.18 Tool G Clutch Hub, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Painted 

Asm

- - - Spray - - - - - -

$16.39 P.-P. Part G Clutch Hub, G Clutch Hub, Isolator, Insert G Clutch Hub, 3.0000 sec 3.0000 sec - $0.04 1

Isolator, Painted Molded Asm Isolator, Insert 

Asm Molded Asm

Media:

$16.39 Tool G Clutch Hub, Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Insert ton

Molded Asm

$20.81 P.-P. Part G Clutch Hub, G Clutch Hub, Isolator, Inner, G Clutch Hub, 3.0000 sec 3.0000 sec - $0.01 1

Isolator, Insert Washed Isolator, Inner, 

Molded Asm Washed

Media:

$20.81 Tool G Clutch Hub, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Inner, 

Washed

Design Profit ®
Page 78 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$42.18 P.-P. Part G Clutch Hub, G Clutch Hub, Isolator, Inner, G Clutch Hub, 3.0000 sec 3.0000 sec - $0.02 1

Isolator, Inner, Deburred Isolator, Inner, 

Washed Deburred

Media:

$42.18 Tool G Clutch Hub, Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Inner, 

Deburred

$19.15 P.-P. Part G Clutch Hub, G Clutch Hub, Isolator, Inner, G Clutch Hub, 3.0000 sec 3.0000 sec - $0.04 1

Isolator, Inner, Machined Isolator, Inner, 

Deburred Machined

Media:

$19.15 Tool G Clutch Hub, CNC Turning 2 Axis SL-10, Odd 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Inner, Form

Machined

Media:

Design Profit ®
Page 79 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$15.50 P.-P. Part G Clutch Hub, G Clutch Hub, Isolator, Inner, G Clutch Hub, 3.0000 sec 3.0000 sec - $0.02 1

Isolator, Inner, Stamped Isolator, Inner, 

Machined Stamped

Media:

x $15.50 Tool G Clutch Hub, Stamping Press 0-60 Ton 0.70 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Inner, 

Stamped

x $15.50 Part G Clutch Hub, G Clutch Hub, Isolator, Inner, G Clutch Hub, 0.0000 sec 0.7000 sec 0.7 $0.13 $0.00 1

Isolator, Inner, Stell Isolator, Inner, 

Stamped Steel

Media:

- - - Blank weight 0.242 lbs - - - - - -

- - - Press Size 60 Ton, Progressive - - - - - -

- - - Part Size (60.2mm Diam by - - - - - -

12.2mm H)

x $19.15 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.02 1

Isolator, Inner, 

Machined

x $19.15 Operation G Clutch Hub, Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.02 1

Isolator, Inner, 

Machined

x $19.15 Material Mod. G Clutch Hub, Turn End face 1-30mm 2.0000 sec 2.0000 sec 2 $0.00 $0.01 1

Isolator, Inner, 

Machined

x $19.15 Operation G Clutch Hub, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.03 1

Isolator, Inner, 

Machined

- - - Combo Tool Used: Drill & Tap - 22.00 - - - - -

Design Profit ®
Page 80 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $19.15 Material Mod. G Clutch Hub, Drill and Tap Hole 1-30mm 5.0000 sec 5.0000 sec 5 $0.00 $0.03 3

Isolator, Inner, 

Machined

x $19.15 Operation G Clutch Hub, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 2

Isolator, Inner, 

Machined

x $19.15 Operation G Clutch Hub, Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Isolator, Inner, 

Machined

x $19.15 Operation G Clutch Hub, Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.01 1

Isolator, Inner, 

Machined Debur 8.00

- - - Batch - - - - - -

x $42.18 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Isolator, Inner, 

Deburred

x $42.18 Material Mod. G Clutch Hub, Debur/Tumble 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Isolator, Inner, 

Deburred

x $42.18 Operation G Clutch Hub, Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Isolator, Inner, 

Deburred

- - - In-Line Washer - 18.00 - - - - -

x $20.81 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.02 1

Isolator, Inner, 

Washed

x $20.81 Operation G Clutch Hub, Wash Part Medium 5.0000 sec 5.0000 sec 5 $0.00 $0.03 1

Isolator, Inner, 

Washed

x $20.81 Operation G Clutch Hub, Unload Part 2.0000 sec 2.0000 sec 2 $0.00 $0.01 1

Isolator, Inner, 

Washed

x $16.39 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Isolator, Insert 3

Molded Asm
Design Profit

®

Page 81 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $20.81 P.-P. Part G Clutch Hub, G Clutch Hub, Isolator, Outer, G Clutch Hub, 5.0000 sec 5.0000 sec 5 - $0.02 1

Isolator, Insert Washed Isolator, Outer, 

Molded Asm Washed

Media:

$20.81 Tool G Clutch Hub, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Outer, 

Washed

$42.18 P.-P. Part G Clutch Hub, G Clutch Hub, Isolator, Outer, G Clutch Hub, 3.0000 sec 3.0000 sec - $0.02 1

Isolator, Outer, Deburred Isolator, Outer, 

Washed Deburred

Media:

$42.18 Tool G Clutch Hub, Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Outer, 

Deburred

$15.50 P.-P. Part G Clutch Hub, G Clutch Hub, Isolator, Outer, G Clutch Hub, 3.0000 sec 3.0000 sec - $0.04 1

Isolator, Outer, Stamped Isolator, Outer, 0.70

Deburred Stamped

Media:

x $15.50 Tool G Clutch Hub, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Outer, 

Stamped

x $15.50 Part G Clutch Hub, G Clutch Hub, Isolator, Outer, G Clutch Hub, 0.0000 sec 0.7000 sec 0.7 $0.17 $0.00 1

Isolator, Outer, Steel Isolator, Outer, 

Stamped Steel

Design Profit ®

Page 82 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Blank weight 0.307 lbs - - - - - -

- - - Press Size 60 Ton, Progressive - - - - - -

- - - Part Size (100mm Diam by 13mm - - - - - -

H)

- - - Batch - - - - - -

x $42.18 Operation G Clutch Hub, Load Part 11.00 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Isolator, Outer, 

Deburred

x $42.18 Material Mod. G Clutch Hub, Debur/Tumble 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Isolator, Outer, 

Deburred

x $42.18 Operation G Clutch Hub, Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Isolator, Outer, 

Deburred

- - - In-Line Washer - 13.00 - - - - -

x $20.81 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.02 1

Isolator, Outer, 

Washed

x $20.81 Operation G Clutch Hub, Wash Part Medium 5.0000 sec 5.0000 sec 5 $0.00 $0.03 1

Isolator, Outer, 

Washed

x $20.81 Operation G Clutch Hub, Unload Part 2.0000 sec 2.0000 sec 2 $0.00 $0.01 1

Isolator, Outer, 

Washed

x $16.39 Operation G Clutch Hub, Load Part 5.00 3.0000 sec 3.0000 sec 3 $0.00 $0.01 1

Isolator, Insert 

Molded Asm

x $16.39 Part G Clutch Hub, G Clutch Hub, Isolator, SBR G Clutch Hub, 0.0000 sec 33.0300 sec $0.09 $0.15 1

Isolator, Insert Isolator, SBR

Molded Asm

Media:

Stamp 33.03

x $16.39 Operation G Clutch Hub, Unload Part 2.0000 sec 2.0000 sec 2 $0.00 $0.01 1

Isolator, Insert 

Molded Asm

- - - Raw Material Req 0.081 lbs - - - - - -

Design Profit ®

Page 83 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Paint Score Cost (Total)

- - - 6 Cavity Mold - - - - - -

- - - Box Size 83mm Diam x 13mm H - - - - - -

$42.18 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Isolator, Painted 

Asm

$42.18 Operation G Clutch Hub, Paint Part Small 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Isolator, Painted 

Asm

$42.18 Tool G Clutch Hub, Oven 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Painted 

Asm

- - - This Oven time is for a small - - - - - -

Batch part

$42.18 Operation G Clutch Hub, Paint Oven Cure 60.0000 sec 60.0000 sec 60 $0.00 $0.70 1

Isolator, Painted 

Asm

$42.18 Operation G Clutch Hub, Unload Part 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Isolator, Painted 

Asm

$0.00 Part G Clutch Hub G Clutch Hub, Washer, M5 G Clutch Hub, 4.0000 sec 4.0000 sec 4 $0.00 $0.00 3

Asm Washer, M5

Media:

$42.18 P.-P. Part G Clutch Hub G Clutch Hub, Face G Clutch Hub, 3.0000 sec 3.0000 sec - $0.00 1

Asm Face

Media:

$42.18 Tool G Clutch Hub, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Face

- - - Spray - - - - - -

Design Profit ®

Page 84 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$20.81 P.-P. Part G Clutch Hub, G Clutch Hub, Face, Washed G Clutch Hub, 3.0000 sec 3.0000 sec - $0.04 1

Face Face, Washed

Media:

$20.81 Tool G Clutch Hub, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Face, Washed

x $42.18 P.-P. Part G Clutch Hub, G Clutch Hub, Face, Deburred G Clutch Hub, 3.0000 sec 3.0000 sec - $0.02 1

Face, Washed Face, Deburred

Media:

x $42.18 Tool G Clutch Hub, G Clutch Hub, Deburing Equipment Deburing Equipment 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 1

Face, Deburred

x $19.15 P.-P. Part G Clutch Hub, G Clutch Hub, Face, Machined G Clutch Hub, 3.0000 sec 3.0000 sec - $0.04 1

Face, Deburred Face, Deburred-1

Media:

x $19.15 Tool G Clutch Hub, CNC Turning 2 Axis SL-10, Odd 0.0000 sec 0.0000 sec $0.00 $0.00 1

Face, Machined Form

Media:

Design Profit ®

Page 85 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $42.91 P.-P. Part G Clutch Hub, G Clutch Hub, Face, Stamped G Clutch Hub, 2.00 3.0000 sec 3.0000 sec 3 - $0.02 1

Face, Machined Face, Stamped

Media:

x $42.91 Tool G Clutch Hub, Stamping Press 200-400 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Face, Stamped

x $42.91 Part G Clutch Hub, G Clutch Hub, Face, Steel G Clutch Hub, 0.0000 sec 2.0000 sec 2 $0.64 $0.02 1

Face, Stamped Face, Steel

Media:

- - - Blank weight 1.167 lbs Blank weight 1.167 lbs - - - - - -

- - - Press Size 400 Ton Progressive - - - - - -

- - - Part Size 108 mm Diam by - - - - - -

4.7mm H

x $19.15 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.02 1

Face, Machined

x $19.15 Operation G Clutch Hub, Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.02 1

Face, Machined

x $19.15 Material Mod. G Clutch Hub, Turn End face 1-30mm 2.0000 sec 2.0000 sec 2 $0.00 $0.01 1

Face, Machined

x $19.15 Operation G Clutch Hub, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.03 1

Face, Machined

- - - Counterbore Rivit Relief - 18.00 - - - - -

Media:

Design Profit ®

Page 86 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $19.15 Material Mod. G Clutch Hub, Counter Bore Hole Small 1.0000 sec 1.0000 sec 1 $0.00 $0.01 3

Face, Machined

x $19.15 Operation G Clutch Hub, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 2

Face, Machined

x $19.15 Operation G Clutch Hub, Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Face, Machined

x $19.15 Operation G Clutch Hub, Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.01 1

Face, Machined

- - - Batch - - - - - -

x $42.18 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Face, Deburred

$42.18 Material Mod. G Clutch Hub, Debur/Tumble 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Face, Deburred

x $42.18 Operation G Clutch Hub, Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Face, Deburred

- - - In-Line Washer - 13.00 - - - - -

x $20.81 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.02 1

Face, Washed

x $20.81 Operation G Clutch Hub, Wash Part Medium 5.0000 sec 5.0000 sec 5 $0.00 $0.03 1

Face, Washed

x $20.81 Operation G Clutch Hub, Unload Part 2.0000 sec 2.0000 sec 2 $0.00 $0.01 1

Face, Washed

x $42.18 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Face

x $42.18 Operation G Clutch Hub, Paint Part Small 3.0000 sec 3.0000 sec 3 $0.00 $0.04 1

Face

x $42.18 Tool G Clutch Hub, Oven 0.0000 sec 0.0000 sec $0.00 $0.00 1

Face

- - - This Oven time is for a small - - - - - -

Batch part

$42.18 Operation G Clutch Hub, Paint Oven Cure 71.00 60.0000 sec 60.0000 sec 60 $0.00 $0.70 1

Face

$42.18 Operation G Clutch Hub, Unload Part 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Face

- - - 3 Rivets Swaged at Once - - - - - -

$0.00 Material Mod. G Clutch Hub Swage 1.0000 sec 1.0000 sec $0.00 $0.00 1

Asm

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 87 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$37.60 P.-P. Part G Clutch Hub G Clutch Hub, Splined Hub, G Clutch Hub, 6.0000 sec 6.0000 sec - $0.00 1

Asm Painted Splined Hub, 

Painted

Media:

x $37.60 Tool G Clutch Hub, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Splined Hub, 

Painted

- - - Spray - - - - - -

x $20.81 P.-P. Part P.-P. Part G Clutch Hub, G Clutch Hub, G Clutch Hub, Splined Hub, G Clutch Hub, Splined Hub, G Clutch Hub, G Clutch Hub, 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec - $0.03 1

Splined Hub, Washed Splined Hub, 

Painted Washed

Media:

x $20.81 Tool G Clutch Hub, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Splined Hub, 

Washed

Design Profit ®

Page 88 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $37.60 P.-P. Part G Clutch Hub, G Clutch Hub, Splined Hub, G Clutch Hub, 3.0000 sec 3.0000 sec - $0.02 1

Splined Hub, Broached Splined Hub, 

Washed Broached

Media:

x $37.60 Tool G Clutch Hub, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Splined Hub, 

Broached

x $30.84 P.-P. Part G Clutch Hub, G Clutch Hub, Splined Hub, CNC G Clutch Hub, 3.0000 sec 3.0000 sec - $0.03 1

Splined Hub, Turned Splined Hub, 

Broached CNC Turned

Media:

x $30.84 Tool G Clutch Hub, CNC Turning 4 Axis SL-10, 1.75 0.0000 sec 0.0000 sec $0.00 $0.00 1

Splined Hub, bar

CNC Turned

Media:

- - - Includes Bar Feeder - - - - - -

Media:

Design Profit ®

Page 89 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $30.84 Part G Clutch Hub, G Clutch Hub, Center Hub, G Clutch Hub, 3.0000 sec 3.0000 sec 3 $0.39 $0.03 1

Splined Hub, Splined, Steel Bar Center Hub, 

CNC Turned Splined, Steel 

Bar 3.00

Media:

- - - Bar Stock, 45mm Diam x 19mm - - - - - -

H, 0.523 LB

- - - Finished Part, 45mm Diam x - - - - - -

179mm H

- - - Machine Part to Part Mating Face - - - - - -

Media:

x $30.84 Material Mod. G Clutch Hub, Turn end face 1-30mm 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Splined Hub, 

CNC Turned

- - - Drill Shaft Mating Hole - 8.00 - - - - -

Media:

x $30.84 Operation G Clutch Hub, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.04 1

Splined Hub, 

CNC Turned

x $30.84 Material Mod. G Clutch Hub, Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Splined Hub, 

CNC Turned

Design Profit ®

Page 90 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Drill 3 M6 Holes - 7.00 - - - - -

Media:

x $30.84 Operation G Clutch Hub, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.04 1

Splined Hub, 

CNC Turned

x $30.84 Material Mod. G Clutch Hub, Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 3

Splined Hub, 

CNC Turned

x $30.84 Operation G Clutch Hub, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 2

Splined Hub, 

CNC Turned

- - - Drill 3 3.75mm Holes - 7.00 - - - - -

Media:

x $30.84 Operation G Clutch Hub, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.04 1

Splined Hub, 

CNC Turned

x $30.84 Material Mod. G Clutch Hub, Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec 1 $0.00 $0.01 3

Splined Hub, 

CNC Turned

x $30.84 Operation G Clutch Hub, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 2

Splined Hub, 

CNC Turned

Design Profit ®
Page 91 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Machine Shaft Hub Portion - 10.00 - - - - -

Media:

x $30.84 Operation G Clutch Hub, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.04 1

Splined Hub, 

CNC Turned

x $30.84 Material Mod. G Clutch Hub, Turn End face 1-30mm 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Splined Hub, 

CNC Turned

x $30.84 Operation G Clutch Hub, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Splined Hub, 

CNC Turned

x $30.84 Material Mod. G Clutch Hub, Turn End face 1-30mm 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Splined Hub, 

CNC Turned

- - - Cut Piece from Bar with Parting Cut Piece from Bar with Parting - 8.00 - - - - -

Tool 

- - - Grab Turned Piece with 2nd - - - - - -

Chuck Head

x $30.84 Operation G Clutch Hub, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.04 1

Splined Hub, 

CNC Turned

x $30.84 Material Mod. G Clutch Hub, Turn End face 1-30mm 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Splined Hub, 

CNC Turned

x $30.84 Operation G Clutch Hub, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Splined Hub, 

CNC Turned

- - - Chamfer Hub at Parting Area - 11.00 - - - - -

Media:

Design Profit ®
Page 92 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $30.84 Operation G Clutch Hub, Auto Tool Change 5.0000 sec 5.0000 sec 5 $0.00 $0.04 1

Splined Hub, 

CNC Turned

x $30.84 Material Mod. G Clutch Hub, Turn End face 1-30mm 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Splined Hub, 

CNC Turned

x $30.84 Operation G Clutch Hub, CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Splined Hub, 

CNC Turned

x $30.84 Material Mod. G Clutch Hub, Turn End face 1-30mm 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Splined Hub, 

CNC Turned

x $30.84 Operation G Clutch Hub, Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Splined Hub, Broach 13.50

CNC Turned

x $37.60 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec 1 $0.00 $0.03 1

Splined Hub, 

Broached

x $37.60 Operation G Clutch Hub, Clamp Part 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Splined Hub, 

Broached

x $37.60 Material Mod. G Clutch Hub, Broach Steel 1 ft lng tool 1.5000 sec 1.5000 sec 1.5 $0.00 $0.02 1

Splined Hub, 

Broached

x $37.60 Operation G Clutch Hub, Unclamp Part 1.0000 sec 1.0000 sec 1 $0.00 $0.01 1

Splined Hub, 

Broached

x $37.60 Operation G Clutch Hub, Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Splined Hub, 

Broached

- - - In-Line Washer - 13.00 - - - - -

x $20.81 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.02 1

Splined Hub, 

Washed

x $20.81 Operation G Clutch Hub, Wash Part Medium 5.0000 sec 5.0000 sec 5 $0.00 $0.03 1

Splined Hub, 

Washed

x $20.81 Operation G Clutch Hub, Unload Part 2.0000 sec 2.0000 sec 2 $0.00 $0.01 1

Splined Hub, 

Washed

x $37.60 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Splined Hub, 

Painted
Design Profit

®

Page 93 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $37.60 Operation G Clutch Hub, Paint Part Small 65.00 3.0000 sec 3.0000 sec 3 $0.00 $0.03 1

Splined Hub, 

Painted

x $37.60 Tool G Clutch Hub, Oven 0.0000 sec 0.0000 sec $0.00 $0.00 1

Splined Hub, 

Painted

- - - This Oven time is for a small - - - - - -

Batch part

x $37.60 Operation G Clutch Hub, Paint Oven Cure 60.0000 sec 60.0000 sec 60 $0.00 $0.63 1

Splined Hub, 

Painted

x $37.60 Operation G Clutch Hub, Unload Part 2.0000 sec 2.0000 sec 2 $0.00 $0.02 1

Splined Hub, Assembly 25.00

Painted

x $0.00 Operation G Clutch Hub Align to Base 2.0000 sec 2.0000 sec 2 $0.00 $0.00 1

Asm

x $0.00 Part G Clutch Hub G Clutch Hub, Rivet Pin, M6 G Clutch Hub, 7.0000 sec 7.0000 sec 7 $0.00 $0.00 3

Asm Rivet Pin, M6

Media:

- - - 3 Rivets Swaged at Once - - - - - -

x $0.00 Material Mod. G Clutch Hub Swage 1.0000 sec 1.0000 sec 1 $0.00 $0.00 1

Asm

x $0.00 Fastening G AC Systems Set In Place 1.0000 sec 1.0000 sec 1 $0.00 $0.00 1

Media:
Design Profit

®

Page 94 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $0.00 Part G AC Systems G Bolt, Clutch Hub G Bolt, Clutch 6.0000 sec 6.0000 sec 6 $0.00 $0.00 1

Hub

Media:

x $0.00 Tool G AC Systems Power Tool 4.0000 sec 4.0000 sec 4 $0.00 $0.00 1

x $0.00 Fastening G AC Systems Power Screw 4.0000 sec 4.0000 sec 4 $0.00 $0.00 1

Media:

Design Profit ®

Page 95 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$50.58 P.-P. Part G AC Systems G Clutch Hub, Cover, Molded G Clutch Hub, 6.0000 sec 6.0000 sec - $0.00 1

Cover, Molded

Media:

x $50.58 Tool G Clutch Hub, Inj Molding Machine 400-800 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover, Molded

x $50.58 Part G Clutch Hub, G Clutch Hub, Cover, Material G Clutch Hub, 3.46 0.0000 sec 3.4560 sec $0.21 $0.05 1

Cover, Molded Cover, Material

Media:

Assembly 18.00

- - - Raw Material Req 0.147 lbs - - - - - -

- - - 6 Cavity Mold - - - - - -

- - - Box Size 120mm Dia x 23mm H - - - - - -

x $0.00 Fastening G AC Systems Set In Place 1.0000 sec 1.0000 sec 1 $0.00 $0.00 1

Media:

x $0.00 Part G AC Systems G Bolt, AC Clutch Hub Cover G Bolt, AC Clutch 6.0000 sec 6.0000 sec 6 $0.00 $0.00 3

Hub Cover

Media:

Design Profit ®
Page 96 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $0.00 Tool G AC Systems 3 Spindle Nut Runner 6.0000 sec 6.0000 sec 6 $0.00 $0.00 1

x $0.00 Fastening G AC Systems Power Screw 4.0000 sec 4.0000 sec 4 $0.00 $0.00 1

Media:

x $0.00 Operation G AC Systems CDI 1.0000 sec 1.0000 sec 1 $0.00 $0.00 1

$55.17 P.-P. Part G AC Systems G Bracket, AC Electrical, Zinc G Bracket, AC 7.0000 sec 7.0000 sec - $0.00 1

Plated Electrical, Zinc 

Plated

Media:

$55.17 Tool G Bracket, AC G Bracket, AC Anodizing Equipment Anodizing Equipment 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 1

Electrical, Zinc 

Plated

Media:

- - - Zinc Plating, Batched Processed - - - - - -

Design Profit ®

Page 97 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $20.81 P.-P. Part G Bracket, AC G Bracket, AC Electrical, Washed G Bracket, AC 3.0000 sec 3.0000 sec 3 - $0.05 1

Electrical, Zinc Electrical, 

Plated Washed

Media:

x $20.81 Tool G Bracket, AC Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Electrical, 

Washed

x $15.50 P.-P. Part G Bracket, AC G Bracket, AC Electrical, G Bracket, AC 3.0000 sec 3.0000 sec - $0.02 1

Electrical, Stamped Electrical, 

Washed Stamped

Media:

x $15.50 Tool G Bracket, AC Stamping Press 0-60 Ton 0.60 0.0000 sec 0.0000 sec $0.00 $0.00 1

Electrical, 

Stamped

x $15.50 Part G Bracket, AC G Bracket, AC Electrical, Steel G Bracket, AC 0.0000 sec 0.6000 sec $0.01 $0.00 1

Electrical, Electrical, Steel

Stamped

- - - Blank weight 0.016 lbs - - - - - -

- - - Press Size 25 Ton, Progressive - - - - - -

- - - Part Size (37.8mm L, 23.4mm W, - - - - - -

1.44mm H)

- - - In-Line Washer - - - - - -

x $20.81 Operation G Bracket, AC Load Part 3.0000 sec 3.0000 sec 3 $0.00 $0.02 1

Electrical, 

Washed

x $20.81 Operation G Bracket, AC Wash Part Medium 13.00 5.0000 sec 5.0000 sec 5 $0.00 $0.03 1

Electrical, 

Washed

Design Profit ®

Page 98 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

x $20.81 Operation G Bracket, AC Unload Part 2.0000 sec 2.0000 sec 2 $0.00 $0.01 1

Electrical, 

Washed

x $55.17 Operation G Bracket, AC Load Part 8.82 3.0000 sec 3.0000 sec 3 $0.00 $0.05 1

Electrical, Zinc 

Plated

x $55.17 Operation G Bracket, AC Electroplate Process 0.4176 sec 1.8156 sec 1.8156 $0.00 $0.03 1

Electrical, Zinc 

Plated

- - - Surface area to Plate: 1.38 Sq - - - - - -

Inches 

x $55.17 Operation G Bracket, AC Remove Part 2.0000 sec 2.0000 sec 2 $0.00 $0.03 1

Electrical, Zinc 

Plated

x $0.00 Part G AC Systems G Bolt, Bracket, AC Electrical G Bolt, Bracket, 6.0000 sec 6.0000 sec 6 $0.00 $0.00 1

assemble AC Electrical 14.00

Media:

x $0.00 Tool G AC Systems Power Tool 4.0000 sec 4.0000 sec 4 $0.00 $0.00 1

x $0.00 Fastening G AC Systems Power Screw 4.0000 sec 4.0000 sec 4 $0.00 $0.00 1

Report Totals Count: ##

1,238

Design Profit ®

Page 99 of #

Copyright 2005© Munro & Associates, Inc.
Piece Cost 

(Total)

$0.00

-

$0.00

-

$0.00

-

$0.00

-

$0.00

Piece Cost 

(Total)

-

$0.00

-

-

-

$0.00

Piece Cost 

(Total)

$0.99

$0.00

$0.00

-

-

-

$0.00

$0.00

-

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$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

-

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

$0.55

$0.00

Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$0.00

-

-

-

$0.00

$0.06

-

-

-

$0.00

Piece Cost 

(Total)

$0.11

$0.00

$0.17

$0.00

Piece Cost 

(Total)

$0.12

$0.00

$0.00

$0.00

$0.00
Piece Cost 

(Total)

$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
Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$0.00

$0.00

-

$0.00

-

$0.00

-

Piece Cost 

(Total)

$0.00

-

$0.00

-

$0.00

$1.08

-

-

-

$0.00

$0.00
Piece Cost 

(Total)

-

$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

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

-

Piece Cost 

(Total)

-

$0.00

$0.27

-

-

-

$0.00

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$0.11

$0.00

$0.17

$0.00

Piece Cost 

(Total)

$0.12

$0.00
-

$0.00

$0.05

-

-
Piece Cost 

(Total)

-

$0.00

-

$0.00

-

$0.00
Piece Cost 

(Total)

-

$0.00

-

-

$0.00
Piece Cost 

(Total)

-

-

$0.00

$2.05

-

-

-

$0.00

$0.00

-

$0.00

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$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

-

-

Piece Cost 

(Total)

-

$0.55

$0.00

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

-

-

-

$0.00

Piece Cost 

(Total)

$0.06

-

-

-

$0.00

$0.00

$0.00

$0.00


Piece Cost 

(Total)

-

$0.00

-

-

-

$0.00

-

$0.00

Piece Cost 

(Total)

$0.03

-

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

-

Piece Cost 

(Total)

-

$0.00

-

-

$0.00

Piece Cost 

(Total)

-

$0.00

$0.30

-

-

-

$0.00

$0.00

-

$0.00

-

$0.00

Piece Cost 

(Total)

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

$0.00

-

$0.00

-

Piece Cost 

(Total)

-

$0.00

-

$0.00

$0.02

-

-

-

$0.00

$0.00

$0.00
Piece Cost 

(Total)

-

$0.00

$0.00

$0.00

$0.00

-

$0.00

-

-

$0.00

-
Piece Cost 

(Total)

$0.00

$0.04

-

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

-
Piece Cost 

(Total)

$0.00

$0.00

-

$0.00

$0.04

-

-

$0.00
Piece Cost 

(Total)

-

$0.00

-

$0.00

-

-

-

Piece Cost 

(Total)

$0.00

-

-

-

$0.00

-

-

$0.00

Piece Cost 

(Total)

$0.86

-

-

-

$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

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$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

-

Piece Cost 

(Total)

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

-

-

Piece Cost 

(Total)

-

$0.00

-

$0.00

$0.04

-

-

-

$0.00

$0.00

Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00
Piece Cost 

(Total)

-

$0.00

-

$0.00

-
Piece Cost 

(Total)

$0.00

$0.30

-

-

-

$0.00

$0.00

-

$0.00

-

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.00

Piece Cost 

(Total)

$0.00

$0.00

$0.00

-

-

-

$0.00

-

-

-

-

-

-

-

-

-

-

-

-

-

$0.00

-
Piece Cost 

(Total)

-

$0.00

-

$0.00

$0.02

-

-

-

$0.00

$0.00

$0.00
Piece Cost 

(Total)

-

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

-

-

$0.00

-

-

$0.00

Piece Cost 

(Total)

-

$0.00

$0.04

-

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00
Piece Cost 

(Total)

$0.00

-

$0.00

$0.00

-

$0.00

$0.04

-

-

$0.00

-

-

-
Piece Cost 

(Total)

-

$0.00

-

$0.00

-

$0.00
Piece Cost 

(Total)

-

-

-

$0.00

-

-

$0.00

$0.97

-

-

-
Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

$0.00

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.08
Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

-

$0.00
Piece Cost 

(Total)

$0.00

-

$0.00

$0.00

$0.00

$0.00

-

$0.00
Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

$1.51

$0.00
Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.08

$0.00

Piece Cost 

(Total)

$0.00

$0.00

-

$0.00

$0.00
-

$0.00

$0.00
Piece Cost 

(Total)

-

$0.00

-

-

$0.00

-

$0.00

Piece Cost 

(Total)

-

$0.00

-

$0.00

Piece Cost 

(Total)

-

$0.00

$0.13

-

-

-

$0.00

$0.00

$0.00

$0.00

-

Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

Piece Cost 

(Total)

-

$0.00

-

$0.00

-

$0.00

$0.17
Piece Cost 

(Total)

-

-

-

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.09

$0.00

-

Piece Cost 

(Total)

-

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

-

Piece Cost 

(Total)

-

$0.00

-

$0.00

-

$0.00
Piece Cost 

(Total)

-

$0.00

$0.64

-

-

-

$0.00

$0.00

$0.00

$0.00

-

Piece Cost 

(Total)

$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

-

-

-

Piece Cost 

(Total)

-

-

-

-

-

-

-

$0.00

-

-

$0.00
Piece Cost 

(Total)

-

$0.00

-

$0.00

-
Piece Cost 

(Total)

$0.39

-

-

-

$0.00

-

$0.00

$0.00

Piece Cost 

(Total)

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

Piece Cost 

(Total)

-

$0.00

$0.00

$0.00

$0.00

-

-

$0.00

$0.00

$0.00

-

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.00

Piece Cost 

(Total)

$0.00

$0.00

$0.00
Piece Cost 

(Total)

-

$0.00

$0.21

-

-

-

$0.00

$0.00

Piece Cost 

(Total)

$0.00

$0.00

$0.00

-

$0.00

-

Piece Cost 

(Total)

-

$0.00

-

$0.00

$0.01

-

-

-

-

$0.00

$0.00

Piece Cost 

(Total)

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$12.44
Assembly Report

G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$83.31 Tool G AC Systems First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

$35.51 Subassembly G AC Systems G AC Systems G AC 0.0000 sec 0.0000 sec - $0.00 1

SystemsInstallation

$35.51 Tool G AC Systems First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

$35.51 Subassembly G AC Systems G AC Pump Asm. G AC Pump Asm. 3.0000 sec 3.0000 sec - $0.03 1

$35.51 Tool G AC Pump Asm. First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

$43.52 Subassembly G AC Pump Asm. G Center Pump Asm. G Center Pump 3.0000 sec 3.0000 sec - $0.03 1

Asm.

$43.52 Tool G Center Pump First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm.

$43.52 Subassembly G Center Pump G Rear Pump Housing, Asm. G Rear Pump 4.0000 sec 4.0000 sec - $0.05 1

Asm. Housing, Asm.

$43.52 Tool G Rear Pump First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Asm.

$10.75 P.-P. Part G Rear Pump G Rear Pump Housing, Wash G Rear Pump 4.0000 sec 4.0000 sec - $0.05 1

Housing, Asm. Housing, Wash

$10.75 Tool G Rear Pump Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Wash DRY

$41.20 P.-P. Part G Rear Pump G Rear Pump Housing, Machined G Rear Pump 3.0000 sec 3.0000 sec - $0.01 1

Housing, Wash Housing, 

Machined

$41.20 Tool G Rear Pump EC-300-AL Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Machine

Machined

- - - Pallet Size 300 mm square, 550 - - - - - -

lb Capacity

$43.52 P.-P. Part G Rear Pump G Rear Pump Housing-Trimmed G Rear Pump 4.0000 sec 4.0000 sec - $0.05 1

Housing, Housing-Trimmed

Machined #

- - - Die Cast Trimming - - - - - -

$43.52 Tool G Rear Pump Trim Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing-Trimmed

##### P.-P. Part G Rear Pump G Rear Pump Housing-Cast G Rear 5.0000 sec 7.1400 sec - $0.09 1

Housing-Trimmed Housing-Cast

Design Profit ®

Page 1 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

##### Tool G Rear Pump Die Casting 500 - 1000 ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing-Cast

##### Part G Rear Pump G Rear Pump Housing, Alum G Rear Pump 0.0000 sec 8.7700 sec $0.99 $0.28 1

Housing-Cast Matl Housing, Alum 

Matl

- - - Raw Material Req 0.904 lbs - - - - - -

- - - 4 Cavity Mold - - - - - -

- - - Box Size 4.4" L x 5.2" W x 1" H - - - - - -

$41.20 Operation G Rear Pump Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing, 

Machined

$41.20 Operation G Rear Pump Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing, 

Machined

- - - Front Face - - - - - -

$41.20 Material Mod. G Rear Pump Turn End Face 60-100mm 6.0000 sec 6.0000 sec $0.00 $0.07 1

Housing, 

Machined

$41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. Material Mod. G Rear Pump G Rear Pump Turn OD Med 60-100mm Turn OD Med 60-100mm 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing, 

Machined

$41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Rear Pump Cut Groove Large 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Rear Pump Chamfer OD 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Machined

$41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Rear Pump Spot Face Small 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 5

Housing, 

Machined

Design Profit ®

Page 2 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Operation G Rear Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Rear Pump Bore Hole 30-60mm 2.0000 sec 2.0000 sec $0.00 $0.02 5

Housing, 

Machined

$41.20 Operation G Rear Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Rear Pump Hone Hole 2 inch depth 3.0000 sec 3.0000 sec $0.00 $0.03 5

Housing, 

Machined

$41.20 Operation G Rear Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$41.20 Operation Operation G Rear Pump G Rear Pump Auto Tool Change Auto Tool Change 5.0000 sec 5.0000 sec 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

- - - Step multi-tool - - - - - -

$41.20 Material Mod. G Rear Pump Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 5

Housing, 

Machined

$41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Rear Pump Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

$41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Rear Pump Chamfer Bolt Hole 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

$41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

Design Profit ®
Page 

3 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Material Mod. G Rear Pump Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Rear Pump Chamfer Bolt Hole 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Material Mod. G Rear Pump Drill Hole 30 - 60mm 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Machined

- - - Center Bore - - - - - -

$41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Rear Pump Bore Hole 30-60mm 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Machined

$41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Rear Pump Spot Face 0.5000 sec 0.5000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Rear Pump Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Rear Pump Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing, 

Machined

$41.20 Operation G Rear Pump Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing, 

Machined

- - - Back Face - - - - - -

$41.20 Material Mod. G Rear Pump Turn OD Med 60-100mm 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing, 

Machined

$41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

Design Profit ®

Page 4 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Material Mod. G Rear Pump Spot Face 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Machined

$41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Rear Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

$41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Rear Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 2

Housing, 

Machined

$41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Rear Pump Chamfer Bolt Hole 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

- - - Dual Angle Chamfer on 5 Bore Dual Angle Chamfer on 5 Bore - - - - - -

Holes

$41.20 Operation G Rear Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Rear Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

- - - Combo Tool Dual Chamfer - - - - - -

$41.20 Material Mod. G Rear Pump Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 5

Housing, 

Machined

$41.20 Operation G Rear Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$41.20 Operation G Rear Pump Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Rear Pump Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Machined

Design Profit ®
Page 

5 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$10.75 Operation G Rear Pump Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Housing, Wash

$10.75 Operation G Rear Pump Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 1

Housing, Wash

$10.75 Operation G Rear Pump Remove Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Housing, Wash

- - - Batch Type Washer - - - - - -

- - - 5-10 min cycle time - - - - - -

- - - size 15.75x18.50x25.50 inches x - - - - - -

2

$0.00 Subassembly G Rear Pump G Bearing, Needle, AC Pump G Bearing, 5.0000 sec 5.0000 sec $0.55 $0.06 1

Housing, Asm. Needle, AC 

Pump

$43.52 Tool G Rear Pump Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Asm.

$43.52 Fastening G Rear Pump Press Together 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, Asm.

$43.52 Operation G Rear Pump Change Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, Asm.

$43.52 Material Mod. G Rear Pump Swage 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, Asm.

$43.52 Part G Rear Pump G Rear Pump G Dowel, Small, Rear Housing G Dowel, Small, Rear Housing G Dowel, Small, G Dowel, Small, 6.0000 sec 6.0000 sec 6.0000 sec 6.0000 sec $0.02 $0.07 3

Housing, Asm. Rear Housing

$43.52 Tool G Rear Pump Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, Asm.

$43.52 Operation G Rear Pump Press part 3.0000 sec 3.0000 sec $0.00 $0.04 3

Housing, Asm.

$43.52 Operation G Rear Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, Asm.

$43.52 Part G Rear Pump G O-Ring, Housing, AC Pump G O-Ring, 7.0000 sec 7.0000 sec $0.06 $0.08 1

Housing, Asm. Housing, AC 

Pump

$43.52 Operation G Rear Pump Set O-ring in Place 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, Asm.

$43.52 Operation G Rear Pump Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, Asm.

$43.52 Tool G Rear Pump Label Engraver 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Asm.

$43.52 Operation G Rear Pump Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, Asm.

Design Profit ®

Page 6 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$43.52 Material Mod. G Rear Pump Engrave 4.0000 sec 4.0000 sec $0.00 $0.05 1

Housing, Asm.

$43.52 Part G Rear Pump Small- Self-Adhesive, Printed, Small- 12.0000 sec 12.0000 sec $0.10 $0.15 1

Housing, Asm. Label Self-Adhesive, 

Printed, Label

$43.52 Fastening G Rear Pump Apply Label 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, Asm.

$43.52 Operation G Rear Pump Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, Asm.

$0.00 P.-P. Part G Center Pump G Spacer, Shaft, Large G Spacer, Shaft, 6.0000 sec 6.0000 sec $0.11 $0.07 1

Asm. Large

$43.52 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm.

$0.00 Subassembly G Center Pump G Thrust Bearing, Shaft G Thrust Bearing, 6.0000 sec 6.0000 sec $0.17 $0.07 1

Asm. Shaft

$43.52 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm.

$0.00 P.-P. Part G Center Pump G Spacer, Shaft, Small G Spacer, Shaft, 6.0000 sec 6.0000 sec $0.12 $0.07 1

Asm. Small

$43.52 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm.

$35.51 Subassembly Subassembly G Center Pump G Center Pump G Shaft and Swash Plate Asm. G Shaft and Swash Plate Asm. G Shaft and G Shaft and 6.0000 sec 6.0000 sec 6.0000 sec 6.0000 sec - $0.07 1

Asm. Swash Plate 

Asm.

$35.51 Tool G Shaft and First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Swash Plate 

Asm.

$10.75 P.-P. Part G Shaft and G Shaft, AC Pump G Shaft, AC 3.0000 sec 3.0000 sec - $0.03 1

Swash Plate Pump

Asm.

$10.75 Tool G Shaft, AC Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Pump DRY

$44.85 P.-P. Part G Shaft, AC G Shaft, AC Pump, Wash G Shaft, AC 3.0000 sec 3.0000 sec - $0.01 1

Pump Pump, Wash

$44.85 Tool G Shaft, AC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Pump, Wash

$42.68 P.-P. Part G Shaft, AC G Shaft, AC Pump, Trimmed G Shaft, AC 3.0000 sec 3.0000 sec - $0.04 1

Pump, Wash Pump, Trimmed

$42.68 Tool G Shaft, AC CNC TL-15 2 Axis Twin Spindle 0.0000 sec 0.0000 sec $0.00 $0.00 1

Pump, Trimmed Lathe - Auto Load

- - - Includes Bar Feeder - - - - - -

Design Profit ®
Page 

7 of#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$42.68 Part G Shaft, AC G Shaft, AC Pump, Bar Stock G Shaft, AC 0.0000 sec 0.0000 sec $0.70 $0.00 1

Pump, Trimmed Pump, Bar Stock

- - - Bar stock weight .70 lbs. - - - - - -

- - - Box size of finished part 0.72mm - - - - - -

Dia x 160mm

$42.68 Operation G Shaft, AC Feed Bar Stock 3.0000 sec 3.0000 sec $0.00 $0.04 1

Pump, Trimmed

- - - Turn maximum full length - - - - - -

maximum OD

$42.68 Material Mod. G Shaft, AC Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 3

Pump, Trimmed

$42.68 Operation G Shaft, AC Reposition Cutting Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

- - - Turn .64 OD half length - - - - - -

$42.68 Material Mod. G Shaft, AC Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 2

Pump, Trimmed

$42.68 Operation G Shaft, AC Reposition Cutting Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

- - - Turn .57 OD 1/3 length - - - - - -

$42.68 Material Mod. G Shaft, AC Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump, Trimmed

$42.68 Operation Operation G Shaft, AC G Shaft, AC Reposition Cutting Tool Reposition Cutting Tool 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

- - - Turn .47" OD x 1" length - - - - - -

$42.68 Material Mod. G Shaft, AC Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Reposition Cutting Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

- - - Turn .64 OD x 1" length - - - - - -

$42.68 Material Mod. G Shaft, AC Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Reposition Cutting Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

- - - Turn .67 OD - - - - - -

$42.68 Material Mod. G Shaft, AC Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Reposition Cutting Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

- - - Turn .70 OD - - - - - -

Design Profit ®

Page 8 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$42.68 Material Mod. G Shaft, AC Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Reposition Cutting Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

- - - Turn .55 OD - - - - - -

$42.68 Material Mod. G Shaft, AC Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Reposition Cutting Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

- - - Turn .63 OD - - - - - -

$42.68 Material Mod. G Shaft, AC Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Reposition Cutting Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

- - - Turn .70 OD - - - - - -

$42.68 Material Mod. G Shaft, AC Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Reposition Cutting Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

- - - Turn .68 OD - - - - - -

$42.68 Material Mod. G Shaft, AC Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Reposition Cutting Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

- - - Turn .64 OD - - - - - -

$42.68 Material Mod. G Shaft, AC Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Reposition Cutting Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

- - - Turn .62 OD - - - - - -

$42.68 Material Mod. G Shaft, AC Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Change Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Reposition Cutting Tool 2.0000 sec 2.0000 sec $0.00 $0.02 7

Pump, Trimmed

$42.68 Material Mod. G Shaft, AC Turn I/D Med 60-100 mm 2.0000 sec 2.0000 sec $0.00 $0.02 7

Pump, Trimmed

$42.68 Operation G Shaft, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Pump, Trimmed

Design Profit ®

Page 9 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$42.68 Material Mod. G Shaft, AC Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Pump, Trimmed

$42.68 Material Mod. G Shaft, AC Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Change Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Reposition Cutting Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

$42.68 Material Mod. G Shaft, AC Roll splines small 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Pump, Trimmed

$42.68 Material Mod. G Shaft, AC Cut to Length lrg 4-6 inch 4.0000 sec 4.0000 sec $0.00 $0.05 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

$42.68 Operation G Shaft, AC CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Pump, Trimmed

$42.68 Material Mod. G Shaft, AC Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Change Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Reposition Cutting Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

$42.68 Material Mod. G Shaft, AC Chamfer OD sml 1.0000 sec 1.0000 sec $0.00 $0.01 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Pump, Trimmed

$42.68 Material Mod. G Shaft, AC Roll splines small 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

$42.68 Operation G Shaft, AC Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Pump, Trimmed

$10.75 Operation G Shaft, AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Pump

$10.75 Operation G Shaft, AC Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 1

Pump

Design Profit ®
Page 10 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$10.75 Operation G Shaft, AC Remove Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Pump

- - - Batch Type Washer - - - - - -

- - - 5-10 min cycle time - - - - - -

- - - size 15.75x18.50x25.50 inches x - - - - - -

2

$44.85 P.-P. Part G Shaft and G Swash Plate, AC Pump G Swash Plate, 3.0000 sec 3.0000 sec $0.00 $0.03 1

Swash Plate AC Pump

Asm.

$44.85 Tool G Swash Plate, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Pump

$44.85 Operation G Swash Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

AC Pump

$44.85 Operation G Swash Plate, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

AC Pump

$44.85 Material Mod. G Swash Plate, Broach Steel 1 ft lng tool 1.5000 sec 1.5000 sec $0.00 $0.02 1

AC Pump

- - - 1 Wash Cycles thru machining - - - - - -

$44.85 Operation G Swash Plate, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

AC Pump

$44.85 Operation G Swash Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

AC Pump

$44.85 Operation G Swash Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

AC Pump

$44.85 Operation G Swash Plate, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.06 1

AC Pump

$44.85 Operation G Swash Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

AC Pump

$35.51 Tool G Shaft and Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Swash Plate 

Asm.

$35.51 Fastening G Shaft and Press Together 3.0000 sec 3.0000 sec $0.00 $0.03 1

Swash Plate 

Asm.

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 11 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$43.52 Subassembly G Center Pump G Piston Asm. AC Compressor G Piston Asm. 6.0000 sec 6.0000 sec - $0.07 5

Asm. AC Compressor

$43.52 Tool G Piston Asm. First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 5

AC Compressor

$10.75 P.-P. Part G Piston Asm. G Piston, AC Compressor, G Piston, AC 3.0000 sec 3.0000 sec - $0.04 5

AC Compressor Washed Compressor, 

Washed

$10.75 Tool G Piston, AC Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 5

Compressor, DRY

Washed

$27.47 P.-P. Part G Piston, AC G Piston, AC Compressor, G Piston, AC 3.0000 sec 3.0000 sec - $0.01 5

Compressor, Machine Compressor, 

Washed Machine

$27.47 Tool G Piston, AC CNC Turning 4 Axis SL-10, Odd 0.0000 sec 0.0000 sec $0.00 $0.00 5

Compressor, Form

Machine

$43.52 P.-P. Part P.-P. Part G Piston, AC G Piston, AC G Piston, AC Compressor, G Piston, AC Compressor, G Piston, AC G Piston, AC 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec - $0.02 5

Compressor, Trimmed Compressor, 

Machine Trimmed

$43.52 Tool G Piston, AC Trim Press 0.0000 sec 0.0000 sec $0.00 $0.00 5

Compressor, 

Trimmed

$70.80 P.-P. Part G Piston, AC G Piston, AC Compressor, Cast G Piston, AC 5.0000 sec 6.1600 sec - $0.07 5

Compressor, Compressor, 

Trimmed Cast

$70.80 Tool G Piston, AC Die Casting 0 - 500 ton 0.0000 sec 0.0000 sec $0.00 $0.00 5

Compressor, 

Cast

$70.80 Part G Piston, AC G Piston, AC Compressor, Alum G Piston, AC 0.0000 sec 3.9700 sec $0.22 $0.08 5

Compressor, Mtl Compressor, 

Cast Alum Mtl

- - - Raw Material Req 0.196 lbs - - - - - -

- - - 10 Cavity Mold - - - - - -

- - - Box Size 3" L x 1.22" W x 1" H - - - - - -

Design Profit ®

Page 12 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$27.47 Operation G Piston, AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.02 5

Compressor, 

Machine

- - - END FACES - - - - - -

$27.47 Material Mod. G Piston, AC Turn End Face 30-60mm 4.0000 sec 4.0000 sec $0.00 $0.03 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.02 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.02 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Turn End Face 30-60mm 4.0000 sec 4.0000 sec $0.00 $0.03 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 5

Compressor, 

Machine

- - - OUTSIDE FEATURES - - - - - -

$27.47 Material Mod. G Piston, AC Turn OD 30-60mm 2.0000 sec 2.0000 sec $0.00 $0.02 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Chamfer OD 2.0000 sec 2.0000 sec $0.00 $0.02 5

Compressor, 

Machine

Design Profit ®

Page 13 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$27.47 Operation G Piston, AC Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.02 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.02 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Turn OD 30-60mm 2.0000 sec 2.0000 sec $0.00 $0.02 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Chamfer OD 2.0000 sec 2.0000 sec $0.00 $0.02 5

Compressor, 

Machine

- - - SPECIAL KNURLED ENDS - - - - - -

$27.47 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Knurl OD 2.0000 sec 2.0000 sec $0.00 $0.02 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.02 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.02 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Knurl OD 2.0000 sec 2.0000 sec $0.00 $0.02 5

Compressor, 

Machine

- - - INSIDE FEATURES - - - - - -

- - - SQUARE PADS - - - - - -

$27.47 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Spot Face 2.0000 sec 2.0000 sec $0.00 $0.02 10

Compressor, 

Machine

Design Profit ®

Page 14 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$27.47 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Spot Face 2.0000 sec 2.0000 sec $0.00 $0.02 10

Compressor, 

Machine

- - - BALL SOCKETS - - - - - -

$27.47 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Spot Face 2.0000 sec 2.0000 sec $0.00 $0.02 10

Compressor, 

Machine

$27.47 Operation G Piston, AC Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 5

Compressor, 

Machine

$27.47 Material Mod. G Piston, AC Spot Face 0.5000 sec 0.5000 sec $0.00 $0.00 10

Compressor, 

Machine

$27.47 Operation G Piston, AC Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 5

Compressor, 

Machine

$27.47 Operation G Piston, AC Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 5

Compressor, 

Machine

$10.75 Operation G Piston, AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 5

Compressor, 

Washed

$10.75 Operation G Piston, AC Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 5

Compressor, 

Washed

$10.75 Operation G Piston, AC Remove Part 2.0000 sec 2.0000 sec $0.00 $0.01 5

Compressor, 

Washed

- - - Batch Type Washer - - - - - -

- - - 5-10 min cycle time - - - - - -

- - - size 15.75x18.50x25.50 inches x - - - - - -

2

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 15 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$16.39 P.-P. Part G Piston Asm. G Seal, Piston, AC Compressor G Seal, Piston, 6.0000 sec 6.0000 sec - $0.07 10

AC Compressor AC Compressor

- - - "Injection Molding, Small Size - - - - - -

and/or Low Complexi

$16.39 Tool G Seal, Piston, Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 10

AC Compressor ton

$16.39 Part G Seal, Piston, G Seal, Piston, AC Compressor, G Seal, Piston, 0.0000 sec 0.6110 sec $0.03 $0.00 10

AC Compressor Teflon Mtl AC Compressor, 

Teflon Mtl

- - - Raw Material Req 0.004 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 33.64mm Dia x 5.71mm - - - - - -

H

$43.52 Operation G Piston Asm. Set O-ring in Place 2.0000 sec 2.0000 sec $0.00 $0.02 10

AC Compressor

$43.52 Operation G Piston Asm. Press part 3.0000 sec 3.0000 sec $0.00 $0.04 5

AC Compressor

$0.00 P.-P. Part G Center Pump G Bearing, Swash Plate to Piston G Bearing, 6.0000 sec 6.0000 sec $0.00 $0.07 10

Asm. Swash Plate to 

Piston

$43.52 Operation G Center Pump Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.04 10

Asm.

$0.00 P.-P. Part G Center Pump G Spacer, Shaft, Large G Spacer, Shaft, 6.0000 sec 6.0000 sec $0.11 $0.07 1

Asm. Large

$43.52 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm.

$0.00 Subassembly G Center Pump G Thrust Bearing, Shaft G Thrust Bearing, 6.0000 sec 6.0000 sec $0.17 $0.07 1

Asm. Shaft

$43.52 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm.

$0.00 P.-P. Part G Center Pump G Spacer, Shaft, Small G Spacer, Shaft, 6.0000 sec 6.0000 sec $0.12 $0.07 1

Asm. Small

$43.52 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm.

- - - Space for Printing - - - - - -

Design Profit ®

Page 16 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 17 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$15.50 P.-P. Part G Center Pump G Gasket, Pump Housing G Gasket, Pump 6.0000 sec 6.0000 sec - $0.07 1

Asm. Housing

$15.50 Tool G Gasket, Pump Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing

$15.50 Part G Gasket, Pump G Gasket, Pump Housing, G Gasket, Pump 0.0000 sec 0.7000 sec $0.05 $0.00 1

Housing Material Housing, Material

- - - Blank weight 0.091 lbs - - - - - -

- - - Part Size after stamping (4.62"W - - - - - -

5.2"L 0.0185"H)

- - - Next sub-asm NOT ANALYZED - - - - - -

YET 01-22-10

$43.52 Operation G Center Pump Set In Place 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm.

$43.52 Subassembly G Center Pump G Front Pump Housing, Asm G Front Pump 4.0000 sec 4.0000 sec - $0.05 1

Asm. Housing, Asm

$43.52 Tool G Front Pump First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Asm

$10.75 P.-P. Part G Front Pump G Front Pump Housing, Wash G Front Pump 3.0000 sec 3.0000 sec - $0.04 1

Housing, Asm Housing, Wash

$10.75 Tool G Front Pump Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Wash DRY

$41.20 P.-P. Part G Front Pump G Front Pump Housing, G Front Pump 4.0000 sec 4.0000 sec - $0.01 1

Housing, Wash Machined Housing, 

Machined

$41.20 Tool G Front Pump EC-300-AL Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Machine

Machined

- - - Pallet Size 300 mm square, 550 - - - - - -

lb Capacity

Design Profit ®

Page 18 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$43.52 P.-P. Part G Front Pump G Front Pump Housing, Trimmed G Front Pump 4.0000 sec 4.0000 sec - $0.05 1

Housing, Housing, 

Machined Trimmed

$43.52 Tool G Front Pump Trim Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, 

Trimmed

##### P.-P. Part G Front Pump G Front Pump Housing, Cast G Front Pump 4.0000 sec 29.8000 sec - $0.36 1

Housing, Housing, Raw 

Trimmed Material

- - - "Aluminum Diecasting, Medium - - - - - -

Size and/or Moderate 

##### Tool G Front Pump Die Casting 1000-1800 ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Cast

##### Part G Front Pump G Front Pump Housing, Alum Mtl G Front Pump 0.0000 sec 11.2300 sec $2.05 $0.61 1

Housing, Cast Housing, Alum 

Mtl

- - - Raw Material Req 1.86375 lbs - - - - - -

from Cost Sheet

- - - 4 Cavity Mold - - - - - -

- - - Box Size 5.85mm L x 5.54mm W - - - - - -

x 2.52mm H

$41.20 Operation Operation G Front Pump G Front Pump Load Part Load Part 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing, 

Machined

$41.20 Operation G Front Pump Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing, 

Machined

- - - Front Face - - - - - -

$41.20 Material Mod. G Front Pump Turn End Face 60-100mm 6.0000 sec 6.0000 sec $0.00 $0.07 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Turn OD Med 60-100mm 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

Design Profit ®

Page 19 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Material Mod. G Front Pump Cut Groove Large 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Chamfer OD 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Spot Face Small 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 5

Housing, 

Machined

$41.20 Operation G Front Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. Material Mod. G Front Pump G Front Pump Bore Hole 30-60mm Bore Hole 30-60mm 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec $0.00 $0.02 5

Housing, 

Machined

$41.20 Operation G Front Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Hone Hole 2 inch depth 3.0000 sec 3.0000 sec $0.00 $0.03 5

Housing, 

Machined

$41.20 Operation G Front Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

- - - Step multi-tool - - - - - -

$41.20 Material Mod. G Front Pump Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 5

Housing, 

Machined

Design Profit ®
Page 20 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Operation G Front Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Drill Hole 30 - 60mm 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

- - - Center Bore - - - - - -

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Bore Hole 30-60mm 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Spot Face 0.5000 sec 0.5000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing, 

Machined

$41.20 Operation G Front Pump Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing, 

Machined

- - - Back Face - - - - - -

$41.20 Material Mod. G Front Pump Turn End Face 60-100mm 6.0000 sec 6.0000 sec $0.00 $0.07 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

Design Profit ®

Page 21 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Material Mod. G Front Pump Spot Face 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

$41.20 Operation G Front Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.01 2

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 2

Housing, 

Machined

$41.20 Operation G Front Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation Operation G Front Pump G Front Pump Auto Tool Change Auto Tool Change 5.0000 sec 5.0000 sec 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 2

Housing, 

Machined

$41.20 Operation G Front Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

Design Profit ®
Page 22 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Material Mod. G Front Pump Tap Hole 0.5000 sec 0.5000 sec $0.00 $0.01 3

Housing, 

Machined

$41.20 Operation G Front Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.01 2

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

- - - Dual Angle Chamfer on 5 Bore - - - - - -

Holes

- - - Combo Tool Dual Chamfer - - - - - -

$41.20 Material Mod. G Front Pump Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 5

Housing, 

Machined

$41.20 Operation G Front Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

- - - Interior Angle Hole - - - - - -

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing, 

Machined

$41.20 Operation G Front Pump Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing, 

Machined

- - - Port Face - - - - - -

$41.20 Material Mod. G Front Pump Turn End face 1-30mm 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

Design Profit ®

Page 23 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Tap Hole 0.5000 sec 0.5000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation Operation G Front Pump G Front Pump Auto Tool Change Auto Tool Change 5.0000 sec 5.0000 sec 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Spot Face Small 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Spot Face Small 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing, 

Machined

Design Profit ®
Page 24 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Operation G Front Pump Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing, 

Machined

- - - Mounting Holes - - - - - -

$41.20 Material Mod. G Front Pump Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Spot Face Small 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 2

Housing, 

Machined

$41.20 Operation G Front Pump Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing, 

Machined

$41.20 Material Mod. G Front Pump Spot Face Small 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 2

Housing, 

Machined

$41.20 Operation G Front Pump Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$41.20 Operation G Front Pump Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Machined

$10.75 Operation G Front Pump Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Housing, Wash

$10.75 Operation G Front Pump Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 1

Housing, Wash

$10.75 Operation G Front Pump Remove Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Housing, Wash

- - - Batch Type Washer - - - - - -

- - - 5-10 min cycle time - - - - - -

- - - size 15.75x18.50x25.50 inches x - - - - - -

2

$0.00 Subassembly G Front Pump G Bearing, Needle, AC Pump G Bearing, 5.0000 sec 5.0000 sec $0.55 $0.06 1

Housing, Asm Needle, AC 

Pump

$43.52 Tool G Front Pump Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Asm

$43.52 Fastening G Front Pump Press Together 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, Asm

Design Profit ®

Page 25 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$43.52 Operation G Front Pump Change Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, Asm

$43.52 Material Mod. G Front Pump Swage 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, Asm

$43.52 Part G Front Pump G Dowel, Large Front Housing G Dowel, Large 6.0000 sec 6.0000 sec $0.00 $0.07 2

Housing, Asm Front Housing

$43.52 Tool G Front Pump Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, Asm

$43.52 Operation G Front Pump Press part 3.0000 sec 3.0000 sec $0.00 $0.04 2

Housing, Asm

$43.52 Operation G Front Pump CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, Asm

$43.52 Part G Front Pump G O-Ring, Housing, AC Pump G O-Ring, 7.0000 sec 7.0000 sec $0.06 $0.08 1

Housing, Asm Housing, AC 

Pump

$43.52 Operation G Front Pump Set O-ring in Place 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, Asm

$43.52 Operation G Front Pump Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, Asm

$43.52 Tool G Front Pump Label Engraver 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Asm

$43.52 Operation Operation G Front Pump G Front Pump Clamp Part Clamp Part 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, Asm

$43.52 Material Mod. G Front Pump Engrave 4.0000 sec 4.0000 sec $0.00 $0.05 1

Housing, Asm

$43.52 Part G Front Pump Small- Self-Adhesive, Printed, Small- 12.0000 sec 12.0000 sec $0.10 $0.15 1

Housing, Asm Label Self-Adhesive, 

Printed, Label

$43.52 Fastening G Front Pump Apply Label 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, Asm

$43.52 Operation G Front Pump Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, Asm

$43.52 Part G Center Pump G Bolt, Front to Rear Housing G Bolt, Front to 6.0000 sec 6.0000 sec $0.04 $0.07 3

Asm. Rear Housing

$43.52 Tool G Center Pump 3 Spindle Nut Runner 6.0000 sec 6.0000 sec $0.00 $0.07 1

Asm.

$43.52 Fastening G Center Pump Power Screw 4.0000 sec 4.0000 sec $0.00 $0.05 1

Asm.

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 26 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 27 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 28 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$20.81 P.-P. Part G AC Pump Asm. G Steel Valve, AC Pump G Steel Valve, 6.0000 sec 6.0000 sec - $0.06 1

AC Pump

$20.81 Tool G Steel Valve, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Pump

- - - Completed check of analysis - - - - - - -

1/26/10 - do

- - - In-Line Washer - - - - - -

$42.18 P.-P. Part G Steel Valve, G Steel Valve, AC Pump, G Steel Valve, 6.0000 sec 6.0000 sec - $0.03 1

AC Pump Deburred AC Pump, 

Deburr-1

$42.18 Tool G Steel Valve, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Pump, 

Deburred

$42.91 P.-P. Part G Steel Valve, G Steel Valve, AC Pump, G Steel Valve, 6.0000 sec 6.0000 sec - $0.07 1

AC Pump, Stamped AC Pump, 

Deburred stamped

$42.91 Tool G Steel Valve, Stamping Press 200-400 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Pump, 

Stamped

$42.91 Part G Steel Valve, G Steel Valve, AC Pump, G Steel Valve, 0.0000 sec 1.7000 sec $0.03 $0.02 1

AC Pump, Material AC Pump, 

Stamped Material

- - - Blank weight 0.067 lbs - - - - - -

- - - Press Size 200-400 Ton - - - - - -

Progressive

- - - Part Size after stamping (4.28" - - - - - -

Dia, 0.012" Thick)

Design Profit ®

Page 29 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$42.18 Operation G Steel Valve, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

AC Pump, 

Deburred

$42.18 Material Mod. G Steel Valve, Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.04 1

AC Pump, 

Deburred

$42.18 Operation G Steel Valve, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

AC Pump, 

Deburred

$20.81 Operation G Steel Valve, Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 1

AC Pump

$20.81 Operation G Steel Valve, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.03 1

AC Pump

$20.81 Operation G Steel Valve, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

AC Pump

$35.51 Operation G AC Pump Asm. Align to Housing 2.0000 sec 2.0000 sec $0.00 $0.02 1

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

$20.81 Subassembly G AC Pump Asm. G Valve Plate, Front Cover G Valve Plate, 6.0000 sec 6.0000 sec - $0.06 1

Front Cover

$20.81 Tool G Valve Plate, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Front Cover

- - - Analysis checked - DO - 1/26/10 - - - - - -

$10.75 P.-P. Part G Valve Plate, G Valve Plate, Base, Front G Valve Plate, 4.0000 sec 4.0000 sec - $0.02 1

Front Cover Base, Front

$10.75 Tool G Valve Plate, Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Base, Front DRY

- - - Analysis checked - DO - 1/26/10 - - - - - -

$31.33 P.-P. Part G Valve Plate, G Valve Plate, Base, Wash, , G Valve Plate, 4.0000 sec 4.0000 sec - $0.01 1

Base, Front Front Base, Wash, 

Front

$31.33 Tool G Valve Plate, EC-300-ML Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 1

Base, Wash, , Machine

Front

$42.91 P.-P. Part G Valve Plate, G Valve Plate, Trimmed, Front G Valve Plate, 4.0000 sec 4.0000 sec - $0.03 1

Base, Wash, , Trimmed, Front

Front

Design Profit ®

Page 30 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$42.91 Tool G Valve Plate, Stamping Press 200-400 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Trimmed, Front

$42.91 Part G Valve Plate, G Steel Valve, Valve Plate Base, G Steel Valve, 0.0000 sec 1.7000 sec $0.30 $0.02 1

Trimmed, Front Front Valve Plate Base, 

Front

- - - Blank weight 0.552 lbs - - - - - -

- - - Press Size 200-400 Ton - - - - - -

Progressive

- - - Part Size after stamping (4.28" - - - - - -

Dia., 0.088 Thick)

$31.33 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Base, Wash, , 

Front

$31.33 Operation G Valve Plate, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Base, Wash, , 

Front

- - - GRIND OUTER DIAMETER - - - - - -

$31.33 Material Mod. G Valve Plate, Gound OD 1 inch 2.0000 sec 2.0000 sec $0.00 $0.02 1

Base, Wash, , 

Front

- - - GRIND SURFACE FACES - - - - - -

$31.33 Operation Operation G Valve Plate, G Valve Plate, Auto Tool Change Auto Tool Change 5.0000 sec 5.0000 sec 5.0000 sec 5.0000 sec $0.00 $0.04 1

Base, Wash, , 

Front

$31.33 Material Mod. G Valve Plate, Ground end faces 5.0000 sec 5.0000 sec $0.00 $0.04 1

Base, Wash, , 

Front

$31.33 Operation G Valve Plate, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Base, Wash, , 

Front

$31.33 Material Mod. G Valve Plate, Ground end faces 5.0000 sec 5.0000 sec $0.00 $0.04 1

Base, Wash, , 

Front

- - - REMOVE PART - - - - - -

$31.33 Operation G Valve Plate, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Base, Wash, , 

Front

$31.33 Operation G Valve Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Base, Wash, , 

Front

$10.75 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Base, Front

Design Profit ®

Page 31 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$10.75 Operation G Valve Plate, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 1

Base, Front

$10.75 Operation G Valve Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Base, Front

- - - Batch Type Washer - - - - - -

- - - 5-10 min cycle time - - - - - -

- - - size 15.75x18.50x25.50 inches x - - - - - -

2

$20.81 Operation G Valve Plate, Align to Base 2.0000 sec 2.0000 sec $0.00 $0.01 1

Front Cover

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$10.75 P.-P. Part G Valve Plate, G Valve Plate, Valve G Valve Plate, 4.0000 sec 4.0000 sec - $0.02 1

Front Cover Valve

$10.75 Tool G Valve Plate, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Valve

- - - Analysis checked - DO - 1/26/10 - - - - - -

$42.18 P.-P. Part P.-P. Part G Valve Plate, G Valve Plate, G Valve Plate, Valve G Valve Plate, Valve G Valve Plate, G Valve Plate, 4.0000 sec 4.0000 sec 4.0000 sec 4.0000 sec - $0.01 1

Valve Valve, Deburred

$42.18 Tool G Valve Plate, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Valve

$15.50 P.-P. Part G Valve Plate, G Valve Plate, Valve G Valve Plate, 4.0000 sec 4.0000 sec - $0.05 1

Valve Valve, Stamped

$15.50 Tool G Valve Plate, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Valve

$15.50 Part G Valve Plate, G Valve Plate, Valve G Valve Plate, 0.0000 sec 0.6000 sec $0.02 $0.00 1

Valve Valve

- - - Blank weight 0.024 lbs - - - - - -

- - - Press Size 60 Ton Progressive - - - - - -

- - - Part Size after stamping (2.2" Dia - - - - - -

x 0.015" Thk)

$42.18 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Valve

$42.18 Material Mod. G Valve Plate, Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.04 1

Valve

$42.18 Operation G Valve Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Valve

Design Profit ®

Page 32 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - In-Line Washer - - - - - -

$10.75 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Valve

$10.75 Operation G Valve Plate, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 1

Valve

$10.75 Operation G Valve Plate, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Valve

$20.81 Operation G Valve Plate, Align to Base 2.0000 sec 2.0000 sec $0.00 $0.01 1

Front Cover

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$15.50 P.-P. Part G Valve Plate, G Valve Plate, Top G Valve Plate, 2.0000 sec 2.0000 sec - $0.01 1

Front Cover Top

$15.50 Tool G Valve Plate, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Top

- - - Analysis checked - DO - 1/26/10 - - - - - -

$42.18 P.-P. Part P.-P. Part G Valve Plate, G Valve Plate, G Valve Plate, Top, Deburred G Valve Plate, Top, Deburred G Valve Plate, G Valve Plate, 6.0000 sec 6.0000 sec 6.0000 sec 6.0000 sec - $0.03 1

Top Top, Deburred

$42.18 Tool G Valve Plate, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Top, Deburred

$42.18 P.-P. Part G Valve Plate, G Valve Plate, Top, Stamped G Valve Plate, 6.0000 sec 6.0000 sec - $0.07 1

Top, Deburred Top, Stamped

$42.18 Tool G Valve Plate, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Top, Stamped

$42.18 Part G Valve Plate, G Steel Valve, Top G Steel Valve, 0.0000 sec 0.6000 sec $0.04 $0.01 1

Top, Stamped Top

- - - Blank weight 0.072 lbs - - - - - -

- - - Part Size after stamping (2.2" - - - - - -

Dia., 0.1 Thick)

$42.18 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Top, Deburred

$42.18 Material Mod. G Valve Plate, Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.04 1

Top, Deburred

$42.18 Operation G Valve Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Top, Deburred

- - - In-Line Washer - - - - - -

Design Profit ®

Page 33 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$15.50 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Top

$15.50 Operation G Valve Plate, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.02 1

Top

$15.50 Operation G Valve Plate, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Top

$20.81 Operation G Valve Plate, Insert Pins 2.0000 sec 2.0000 sec $0.00 $0.01 4

Front Cover

$20.81 Part G Valve Plate, G Valve Plate, Pin G Valve Plate, 5.0000 sec 5.0000 sec $0.00 $0.03 4

Front Cover Pin

- - - ALL FOUR PINS SWAGE AT - - - - - -

ONCE

$20.81 Material Mod. G Valve Plate, Swage 1.0000 sec 1.0000 sec $0.00 $0.01 1

Front Cover

$35.51 Operation G AC Pump Asm. Align to Housing 2.0000 sec 2.0000 sec $0.00 $0.02 1

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 34 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$15.50 P.-P. Part G AC Pump Asm. G Gasket, Front Cover G Gasket, Front 6.0000 sec 6.0000 sec - $0.06 1

Cover

$15.50 Tool G Gasket, Front Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover

$15.50 Part G Gasket, Front G Gasket, Front Cover, Material G Gasket, Front 0.0000 sec 0.7000 sec $0.04 $0.00 1

Cover Cover, Material

- - - Blank weight 0.075 lbs - - - - - -

- - - Part Size after stamping (4.28" - - - - - -

Dia., 0.014Thick)

$35.51 Operation G AC Pump Asm. Align to Housing 2.0000 sec 2.0000 sec $0.00 $0.02 1

$43.52 Subassembly G AC Pump Asm. G Front Cover Asm. G Front Cover 6.0000 sec 6.0000 sec - $0.06 1

Asm.

$43.52 Tool G Front Cover First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm.

$10.75 P.-P. Part G Front Cover G Front Cover, Wash G Front Cover, 4.0000 sec 4.0000 sec - $0.05 1

Asm. Wash

$10.75 Tool G Front Cover, Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Wash DRY

$41.20 P.-P. Part G Front Cover, G Front Cover, Machined G Front Cover, 3.0000 sec 3.0000 sec - $0.01 1

Wash Machined

- - - Machining for Trimmed Die Cast - - - - - -

- - - "CNC Mach, Auto Sml Size - - - - - -

and/or Low Complexity"

$41.20 Tool G Front Cover, EC-300-AL Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 1

Machined Machine

- - - Pallet Size 300 mm square, 550 - - - - - -

lb Capacity

$43.52 P.-P. Part G Front Cover, G Front Cover-Trimmed G Front 4.0000 sec 4.0000 sec - $0.05 1

Machined Cover-Trimmed

- - - Die Cast Part Trimming - - - - - -

$43.52 Tool G Front Trim Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover-Trimmed

##### P.-P. Part G Front G Front Cover Asm, Casting G Front Cover 0.0000 sec 7.1300 sec - $0.09 1

Cover-Trimmed Asm, Casting

- - - "Aluminum Diecasting, Medium - - - - - -

Size and/or Moderate 

Design Profit ®

Page 35 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

##### Tool G Front Cover Die Casting 500 - 1000 ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm, Casting

##### Part G Front Cover G Front Cover-Alum Mtl G Front 0.0000 sec 12.1900 sec $0.86 $0.40 1

Asm, Casting Cover-Alum Mtl

- - - Raw Material Req 0.784 lbs - - - - - -

- - - 4 Cavity Mold - - - - - -

- - - Box Size 4.5" L x 5.1" W x 3" H - - - - - -

$41.20 Operation G Front Cover, Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Machined

$41.20 Operation G Front Cover, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Machined

- - - Front Face - - - - - -

$41.20 Material Mod. G Front Cover, Turn End face 1-30mm 2.0000 sec 2.0000 sec $0.00 $0.02 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Turn OD 30-60mm 2.0000 sec 2.0000 sec $0.00 $0.02 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Cut Groove sml 2.0000 sec 2.0000 sec $0.00 $0.02 2

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Turn End face 1-30mm 2.0000 sec 2.0000 sec $0.00 $0.02 1

Machined

$41.20 Operation G Front Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Chamfer OD sml 1.0000 sec 1.0000 sec $0.00 $0.01 2

Machined

- - - Locationg feature - - - - - -

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Machined

Design Profit ®

Page 36 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

- - - Inner groove - - - - - -

$41.20 Material Mod. G Front Cover, Cut Groove sml 2.0000 sec 2.0000 sec $0.00 $0.02 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Chamfer OD sml 1.0000 sec 1.0000 sec $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 5

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Spot Face 0.5000 sec 0.5000 sec $0.00 $0.01 5

Machined

$41.20 Operation G Front Cover, Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 1

Machined

- - - Inside of Outer Lip - - - - - -

$41.20 Material Mod. G Front Cover, Turn OD Med 60-100mm 3.0000 sec 3.0000 sec $0.00 $0.03 1

Machined

$41.20 Operation G Front Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Machined

$41.20 Material Mod. G Front Cover, Turn End Face 60-100mm 6.0000 sec 6.0000 sec $0.00 $0.07 1

Machined

- - - Inner Bore - - - - - -

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Spot Face 2.0000 sec 2.0000 sec $0.00 $0.02 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Machined

Design Profit ®

Page 37 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Material Mod. G Front Cover, Chamfer OD sml 1.0000 sec 1.0000 sec $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Machined

- - - Angled Ports - - - - - -

$41.20 Operation G Front Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Machined

$41.20 Material Mod. G Front Cover, Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Machined

- - - Tab - - - - - -

$41.20 Operation G Front Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Material Mod. G Front Cover, Drill and Tap Hole 1-30mm 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Operation G Front Cover, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Machined

$41.20 Operation G Front Cover, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Machined

$10.75 Operation G Front Cover, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Wash

$10.75 Operation G Front Cover, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 1

Wash

$10.75 Operation G Front Cover, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Wash

- - - Batch Type Washer - - - - - -

- - - 5-10 min cycle time - - - - - -

- - - size 15.75x18.50x25.50 inches x - - - - - -

2

$0.00 Subassembly G Front Cover G Seal, Front Cover G Seal, Front 6.0000 sec 6.0000 sec $0.28 $0.07 1

Asm. Cover

Design Profit ®

Page 38 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$43.52 Operation G Front Cover Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.04 1

Asm.

$43.52 Tool G Front Cover Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm.

$43.52 Fastening G Front Cover Press Together 3.0000 sec 3.0000 sec $0.00 $0.04 1

Asm.

$43.52 Part G Front Cover G Snap-ring, Seal Front Cover G Snap-ring, Seal 6.0000 sec 6.0000 sec $0.00 $0.07 1

Asm. Front Cover

$43.52 Operation G Front Cover CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm.

$43.52 Tool G Front Cover Special Tool 6.0000 sec 6.0000 sec $0.00 $0.07 1

Asm.

$43.52 Fastening G Front Cover Position Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm.

$43.52 Operation G Front Cover CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm.

$43.52 Part G Front Cover G Dust Seal, Cloth, Front Cover G Dust Seal, 3.0000 sec 3.0000 sec $0.00 $0.04 1

Asm. Cloth, Front 

Cover

$43.52 Operation G Front Cover Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.04 1

Asm.

$35.51 Operation Operation G AC Pump Asm. G AC Pump Asm. Press part Press part 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec $0.00 $0.03 1

$35.51 Operation G AC Pump Asm. Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 1

$20.81 P.-P. Part G AC Pump Asm. G Steel Valve, AC Pump G Steel Valve, 6.0000 sec 6.0000 sec - $0.06 1

AC Pump

$20.81 Tool G Steel Valve, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Pump

- - - Completed check of analysis - - - - - - -

1/26/10 - do

- - - In-Line Washer - - - - - -

$42.18 P.-P. Part G Steel Valve, G Steel Valve, AC Pump, G Steel Valve, 6.0000 sec 6.0000 sec - $0.03 1

AC Pump Deburred AC Pump, 

Deburr-1

$42.18 Tool G Steel Valve, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Pump, 

Deburred

$42.91 P.-P. Part G Steel Valve, G Steel Valve, AC Pump, G Steel Valve, 6.0000 sec 6.0000 sec - $0.07 1

AC Pump, Stamped AC Pump, 

Deburred stamped

Design Profit ®

Page 39 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$42.91 Tool G Steel Valve, Stamping Press 200-400 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Pump, 

Stamped

$42.91 Part G Steel Valve, G Steel Valve, AC Pump, G Steel Valve, 0.0000 sec 1.7000 sec $0.04 $0.02 1

AC Pump, Material AC Pump, 

Stamped Material

- - - Blank weight 0.067 lbs - - - - - -

- - - Press Size 200-400 Ton - - - - - -

Progressive

- - - Part Size after stamping (4.28" - - - - - -

Dia, 0.012" Thick)

$42.18 Operation G Steel Valve, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

AC Pump, 

Deburred

$42.18 Material Mod. G Steel Valve, Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.04 1

AC Pump, 

Deburred

$42.18 Operation G Steel Valve, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

AC Pump, 

Deburred

$20.81 Operation G Steel Valve, Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 1

AC Pump

$20.81 Operation G Steel Valve, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.03 1

AC Pump

$20.81 Operation G Steel Valve, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

AC Pump

$35.51 Operation G AC Pump Asm. Align to Housing 2.0000 sec 2.0000 sec $0.00 $0.02 1

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$20.81 Subassembly G AC Pump Asm. G Valve Plate, Rear Cover G Valve Plate, 6.0000 sec 6.0000 sec - $0.06 1

Rear Cover

Design Profit ®

Page 40 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$20.81 Tool G Valve Plate, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Rear Cover

$10.75 P.-P. Part G Valve Plate, G Valve Plate, Base, Rear G Valve Plate, 4.0000 sec 4.0000 sec - $0.02 1

Rear Cover Base, Rear

$10.75 Tool G Valve Plate, Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Base, Rear DRY

$31.33 P.-P. Part G Valve Plate, G Valve Plate, Base, Wash, Rear G Valve Plate, 4.0000 sec 4.0000 sec - $0.01 1

Base, Rear Base, Wash, 

Rear

$31.33 Tool G Valve Plate, EC-300-ML Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 1

Base, Wash, Machine

Rear

$42.91 P.-P. Part G Valve Plate, G Valve Plate, Base, Trimmed G Valve Plate, 4.0000 sec 4.0000 sec - $0.03 1

Base, Wash, Rear Base, Trimmed, 

Rear Rear

$42.91 Tool G Valve Plate, Stamping Press 200-400 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Base, Trimmed 

Rear

$42.91 Part G Valve Plate, G Steel Valve, Valve Plate Base, G Steel Valve, 0.0000 sec 1.7000 sec $0.30 $0.02 1

Base, Trimmed Rear Valve Plate Base, 

Rear Rear

- - - Blank weight 0.552 lbs Blank weight 0.552 lbs - - - - - -

- - - Press Size 200-400 Ton - - - - - -

Progressive

- - - Part Size after stamping (4.28" - - - - - -

Dia., 0.088 Thick)

$31.33 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Base, Wash, 

Rear

$31.33 Operation G Valve Plate, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Base, Wash, 

Rear

- - - GRIND OUTER DIAMETER - - - - - -

$31.33 Material Mod. G Valve Plate, Gound OD 1 inch 2.0000 sec 2.0000 sec $0.00 $0.02 1

Base, Wash, 

Rear

- - - GRIND SURFACE FACES - - - - - -

$31.33 Operation G Valve Plate, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

Base, Wash, 

Rear

Design Profit ®
Page 41 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$31.33 Material Mod. G Valve Plate, Ground end faces 5.0000 sec 5.0000 sec $0.00 $0.04 1

Base, Wash, 

Rear

$31.33 Operation G Valve Plate, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Base, Wash, 

Rear

$31.33 Material Mod. G Valve Plate, Ground end faces 5.0000 sec 5.0000 sec $0.00 $0.04 1

Base, Wash, 

Rear

- - - REMOVE PART - - - - - -

$31.33 Operation G Valve Plate, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Base, Wash, 

Rear

$31.33 Operation G Valve Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Base, Wash, 

Rear

$10.75 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Base, Rear

$10.75 Operation G Valve Plate, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 1

Base, Rear

$10.75 Operation G Valve Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Base, Rear

- - - Batch Type Washer - - - - - -

- - - 5-10 min cycle time - - - - - -

- - - size 15.75x18.50x25.50 inches x - - - - - -

2

$20.81 Operation G Valve Plate, Align to Base 2.0000 sec 2.0000 sec $0.00 $0.01 1

Rear Cover

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 42 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Space for Printing - - - - - -

$10.75 P.-P. Part G Valve Plate, G Valve Plate, Valve G Valve Plate, 4.0000 sec 4.0000 sec - $0.02 1

Rear Cover Valve

$10.75 Tool G Valve Plate, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Valve

- - - Analysis checked - DO - 1/26/10 - - - - - -

$42.18 P.-P. Part G Valve Plate, G Valve Plate, Valve G Valve Plate, 4.0000 sec 4.0000 sec - $0.01 1

Valve Valve, Deburred

$42.18 Tool G Valve Plate, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Valve

$15.50 P.-P. Part G Valve Plate, G Valve Plate, Valve G Valve Plate, 4.0000 sec 4.0000 sec - $0.05 1

Valve Valve, Stamped

$15.50 Tool G Valve Plate, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Valve

$15.50 Part G Valve Plate, G Valve Plate, Valve G Valve Plate, 0.0000 sec 0.6000 sec $0.02 $0.00 1

Valve Valve

- - - Blank weight 0.024 lbs - - - - - -

- - - Press Size 60 Ton Progressive - - - - - -

- - - Part Size after stamping (2.2" Dia - - - - - -

x 0.015" Thk)

$42.18 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Valve

$42.18 Material Mod. G Valve Plate, Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.04 1

Valve

$42.18 Operation G Valve Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Valve

- - - In-Line Washer - - - - - -

$10.75 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Valve

$10.75 Operation G Valve Plate, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 1

Valve

$10.75 Operation G Valve Plate, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Valve

$20.81 Operation G Valve Plate, Align to Base 2.0000 sec 2.0000 sec $0.00 $0.01 1

Rear Cover

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 43 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$15.50 P.-P. Part G Valve Plate, G Valve Plate, Top G Valve Plate, 2.0000 sec 2.0000 sec - $0.01 1

Rear Cover Top

$15.50 Tool G Valve Plate, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Top

- - - Analysis checked - DO - 1/26/10 - - - - - -

$42.18 P.-P. Part G Valve Plate, G Valve Plate, Top, Deburred G Valve Plate, 6.0000 sec 6.0000 sec - $0.03 1

Top Top, Deburred

$42.18 Tool G Valve Plate, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Top, Deburred

$42.18 P.-P. Part G Valve Plate, G Valve Plate, Top, Stamped G Valve Plate, 6.0000 sec 6.0000 sec - $0.07 1

Top, Deburred Top, Stamped

$42.18 Tool G Valve Plate, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Top, Stamped

$42.18 Part G Valve Plate, G Steel Valve, Top G Steel Valve, 0.0000 sec 0.6000 sec $0.04 $0.01 1

Top, Stamped Top

- - - Blank weight 0.072 lbs - - - - - -

- - - Part Size after stamping (2.2" - - - - - -

Dia., 0.1 Thick)

$42.18 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Top, Deburred

$42.18 Material Mod. G Valve Plate, Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.04 1

Top, Deburred

$42.18 Operation G Valve Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Top, Deburred

- - - In-Line Washer - - - - - -

$15.50 Operation G Valve Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Top

$15.50 Operation G Valve Plate, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.02 1

Top

$15.50 Operation G Valve Plate, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Top

$20.81 Operation G Valve Plate, Insert Pins 2.0000 sec 2.0000 sec $0.00 $0.01 4

Rear Cover

$20.81 Part G Valve Plate, G Valve Plate, Pin G Valve Plate, 2.0000 sec 2.0000 sec $0.00 $0.01 4

Rear Cover Pin

- - - ALL FOUR PINS SWAGE AT - - - - - -

ONCE

$20.81 Material Mod. G Valve Plate, Swage 1.0000 sec 1.0000 sec $0.00 $0.01 1

Rear Cover

Design Profit ®

Page 44 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$35.51 Operation G AC Pump Asm. Align to Housing 2.0000 sec 2.0000 sec $0.00 $0.02 1

$15.50 P.-P. Part G AC Pump Asm. G Gasket, Rear Cover G Gasket, Rear 6.0000 sec 6.0000 sec - $0.06 1

Cover

$15.50 Tool G Gasket, Rear Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover

$15.50 Part G Gasket, Rear G Gasket, Rear Cover, Material G Gasket, Rear 0.0000 sec 0.7000 sec $0.04 $0.00 1

Cover Cover, Material

- - - Blank weight 0.08 lbs - - - - - -

- - - Part Size after stamping (4.28" - - - - - -

Dia., 0.015Thick)

$35.51 Operation G AC Pump Asm. Align to Housing 2.0000 sec 2.0000 sec $0.00 $0.02 1

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$43.52 Subassembly G AC Pump Asm. G Rear Cover Asm G Rear Cover 6.0000 sec 6.0000 sec - $0.06 1

Asm

$43.52 Tool G Rear Cover First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm

$10.75 P.-P. Part G Rear Cover G Rear Cover, Washed G Rear Cover, 3.0000 sec 3.0000 sec - $0.04 1

Asm Washed

$10.75 Tool G Rear Cover, G Rear Cover, Washer Duo 400 W sher Duo 400 Wash Rinse & ash Rinse & 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 1

Washed DRY

$41.20 P.-P. Part G Rear Cover, G Rear Cover, Mach G Rear Cover, 4.0000 sec 4.0000 sec - $0.01 1

Washed Mach

$41.20 Tool G Rear Cover, EC-300-AL Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 1

Mach Machine

- - - Pallet Size 300 mm square, 550 - - - - - -

lb Capacity

$43.52 P.-P. Part G Rear Cover, G Rear Cover, Trimmed G Rear Cover, 3.0000 sec 3.0000 sec - $0.03 1

Mach Trimmed

- - - Die Cast Part Trimming - - - - - -

$43.52 Tool G Rear Cover, Trim Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Trimmed

$70.80 P.-P. Part G Rear Cover, G Rear Cover, Casting G Rear Cover, 6.0000 sec 7.1400 sec - $0.09 1

Trimmed Casting

- - - "Aluminum Diecasting, Medium - - - - - -

Size and/or Moderate 

$70.80 Tool G Rear Cover, Die Casting 500 - 1000 ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Casting

Design Profit ®

Page 45 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$70.80 Part G Rear Cover, G Rear Cover, Alum Mtl G Rear Cover, 0.0000 sec 8.2800 sec $0.97 $0.16 1

Casting Alum Mtl

- - - Raw Material Req 0.884 lbs - - - - - -

- - - 4 Cavity Mold - - - - - -

- - - Box Size 4.5" L x 5.1" W x 1.4" H - - - - - -

$41.20 Operation G Rear Cover, Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Mach

$41.20 Operation G Rear Cover, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Mach

- - - Back Face - - - - - -

$41.20 Material Mod. G Rear Cover, Mill Flat Med 4.0000 sec 4.0000 sec $0.00 $0.05 1

Mach

$41.20 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Mach

$41.20 Material Mod. G Rear Cover, Turn I/D Med 60-100 mm 2.0000 sec 2.0000 sec $0.00 $0.02 1

Mach

$41.20 Operation G Rear Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Mach

$41.20 Material Mod. G Rear Cover, Spot Face Small 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Mach

$41.20 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Mach

$41.20 Material Mod. G Rear Cover, Chamfer ID Lrg 2.0000 sec 2.0000 sec $0.00 $0.02 1

Mach

$41.20 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Mach

$41.20 Material Mod. G Rear Cover, Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 2

Mach

$41.20 Operation G Rear Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Mach

$41.20 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Mach

$41.20 Material Mod. G Rear Cover, Tap Hole 2.0000 sec 2.0000 sec $0.00 $0.02 2

Mach

$41.20 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Mach

$41.20 Material Mod. G Rear Cover, Drill and Tap Hole 1-30mm 5.0000 sec 5.0000 sec $0.00 $0.06 3

Mach

$41.20 Operation G Rear Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 2

Mach

Design Profit ®

Page 46 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Mach

- - - CENTER BORE - - - - - -

$41.20 Material Mod. G Rear Cover, Drill and Tap Hole 1-30mm 5.0000 sec 5.0000 sec $0.00 $0.06 1

Mach

$41.20 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Mach

$41.20 Material Mod. G Rear Cover, Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 1

Mach

$41.20 Operation G Rear Cover, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Mach

$41.20 Operation G Rear Cover, Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 1

Mach

$41.20 Operation G Rear Cover, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Mach

- - - FRONT SIDE - - - - - -

$41.20 Material Mod. G Rear Cover, Spot Face 2.0000 sec 2.0000 sec $0.00 $0.02 3

Mach

$41.20 Operation G Rear Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Mach

- - - CENTER BORE - - - - - -

$41.20 Material Mod. Material Mod. G Rear Cover, G Rear Cover, Spot Face Spot Face 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec $0.00 $0.02 1

Mach

$41.20 Material Mod. G Rear Cover, Counter Bore Hole Small 1.0000 sec 1.0000 sec $0.00 $0.01 1

Mach

$41.20 Operation G Rear Cover, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Mach

$41.20 Operation G Rear Cover, Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 1

Mach

$41.20 Operation G Rear Cover, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Mach

- - - SIDE MOUNTING HOLES - - - - - -

$41.20 Material Mod. G Rear Cover, Bore Hole 60-100mm 3.0000 sec 3.0000 sec $0.00 $0.03 2

Mach

$41.20 Operation G Rear Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Mach

$41.20 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Mach

$41.20 Material Mod. G Rear Cover, Spot Face Small 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 2

Mach

Design Profit ®

Page 47 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Operation G Rear Cover, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Mach

$41.20 Material Mod. G Rear Cover, Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 2

Mach

$41.20 Operation G Rear Cover, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Mach

$41.20 Operation G Rear Cover, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Mach

$41.20 Operation G Rear Cover, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Mach

$10.75 Operation G Rear Cover, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Washed

$10.75 Operation G Rear Cover, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 1

Washed

$10.75 Operation G Rear Cover, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Washed

- - - Batch Type Washer - - - - - -

- - - 5-10 min cycle time - - - - - -

- - - size 15.75x18.50x25.50 inches x - - - - - -

2

$43.52 Part G Rear Cover G O-ring, Plug, Rear Cover G O-ring, Plug, 4.0000 sec 4.0000 sec $0.00 $0.05 1

Asm Rear Cover

$43.52 Operation G Rear Cover Set O-ring in Place 2.0000 sec 2.0000 sec $0.00 $0.02 1

Asm

$0.00 Subassembly G Rear Cover G Plug Asm. , Rear Cover G Plug Asm. , 6.0000 sec 6.0000 sec $1.25 $0.07 1

Asm Rear Cover

$43.52 Tool G Rear Cover Power Tool 4.0000 sec 4.0000 sec $0.00 $0.05 1

Asm

$43.52 Fastening G Rear Cover Power Screw 4.0000 sec 4.0000 sec $0.00 $0.05 1

Asm

$35.51 Operation G AC Pump Asm. Press part 3.0000 sec 3.0000 sec $0.00 $0.03 1

$35.51 Operation G AC Pump Asm. Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 1

$35.51 Part G AC Pump Asm. G Bolt, Front Cover to Rear G Bolt, Front 6.0000 sec 6.0000 sec $0.24 $0.06 5

Cover to Rear

$35.51 Tool G AC Pump Asm. 5 Spindle Nut Runner 6.0000 sec 6.0000 sec $0.00 $0.06 1

$35.51 Fastening G AC Pump Asm. Power Screw 4.0000 sec 4.0000 sec $0.00 $0.04 1

$29.69 Subassembly G AC Systems G Magnet Asm., AC Clutch G Magnet Asm., 6.0000 sec 6.0000 sec - $0.06 1

AC Clutch

$29.69 Tool G Magnet Asm., First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Clutch

Design Profit ®

Page 48 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Complete - DO - 2/2/10 - - - - - -

$29.69 Subassembly G Magnet Asm., G Magnet Asm, Potted G Magnet Asm, 5.0000 sec 5.0000 sec - $0.04 1

AC Clutch Potted

$29.69 Tool G Magnet Asm, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Potted

$10.75 Subassembly G Magnet Asm, G Magnet Asm, Housing, G Magnet Asm, 3.0000 sec 3.0000 sec - $0.02 1

Potted Weldment, Washed Housing, 

Weldment, 

Washed

$10.75 Tool G Magnet Asm, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, 

Weldment, 

Washed

$44.96 Subassembly G Magnet Asm, G Magnet Asm, Housing, G Magnet Asm, 3.0000 sec 3.0000 sec - $0.01 1

Housing, Weldment Housing, 

Weldment, Weldment

Washed

$44.96 Tool G Magnet Asm, Spot Weld Fixture 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, 

Weldment

$10.75 P.-P. Part G Magnet Asm, G Magnet Asm, Housing, G Magnet Asm, 3.0000 sec 3.0000 sec - $0.04 1

Housing, Washed Housing, Washed

Weldment

$10.75 Tool G Magnet Asm, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Washed

$37.60 P.-P. Part G Magnet Asm, G Magnet Asm, Housing, G Magnet Asm, 2.0000 sec 2.0000 sec - $0.01 1

Housing, Washed Deburred Housing, 

Deburred

$37.60 Tool G Magnet Asm, Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, 

Deburred

$42.18 P.-P. Part G Magnet Asm, G Magnet Asm, Housing, G Magnet Asm, 3.0000 sec 3.0000 sec - $0.03 1

Housing, Machined Housing, 

Deburred Machined

$42.18 Tool G Magnet Asm, CNC Turning 2 Axis SL-40, 4" bar 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, 

Machined

$42.18 P.-P. Part G Magnet Asm, G Magnet Asm, Housing Formed G Magnet Asm, 0.0000 sec 0.0000 sec - $0.00 1

Housing, Housing Formed

Machined

$42.18 Tool G Magnet Asm, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing Formed

Design Profit ®
Page 49 of

#

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$42.18 Part G Magnet Asm, G Magnet Asm, Housing, Material G Magnet Asm, 0.0000 sec 0.6000 sec $0.75 $0.01 1

Housing Formed Housing, Material

- - - Blank weight 1.665 lbs - - - - - -

- - - Press Size 60 Ton Progressive - - - - - -

- - - Part Size after stamping - 3.9" dia - - - - - -

x 1"Thick

$42.18 Operation G Magnet Asm, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, 

Machined

$42.18 Material Mod. G Magnet Asm, Turn OD Med 60-100mm 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, 

Machined

$42.18 Material Mod. G Magnet Asm, Cut to Length 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Machined

$42.18 Operation G Magnet Asm, Change Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Machined

$42.18 Material Mod. G Magnet Asm, Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$42.18 Operation Operation G Magnet Asm, G Magnet Asm, Change Tool Change Tool 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Machined

$42.18 Material Mod. G Magnet Asm, End Mill Slot Cut 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Machined

$42.18 Operation G Magnet Asm, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Machined

- - - Box size of finished part 4" D x - - - - - -

1.2" 

- - - Steel Housing finished weight = - - - - - -

0.80 lb

$37.60 Operation G Magnet Asm, Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing, 

Deburred

$37.60 Material Mod. G Magnet Asm, Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing, 

Deburred

Design Profit ®

Page 50 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$37.60 Operation G Magnet Asm, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Deburred

$10.75 Operation G Magnet Asm, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Housing, Washed

$10.75 Operation G Magnet Asm, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 1

Housing, Washed

$10.75 Operation G Magnet Asm, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Housing, Washed

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$20.81 P.-P. Part P.-P. Part G Magnet Asm, G Magnet Asm, G Magnet Asm, Backing Plate G Magnet Asm, Backing Plate G Magnet Asm, G Magnet Asm, 5.0000 sec 5.0000 sec 5.0000 sec 5.0000 sec - $0.06 1

Housing, Backing Plate

Weldment

$20.81 Tool G Magnet Asm, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Backing Plate

$42.18 P.-P. Part G Magnet Asm, G Magnet Asm, Backing Plate, G Magnet Asm, 3.0000 sec 3.0000 sec - $0.02 1

Backing Plate Deburred Backing Plate, 

Deburred

$42.18 Tool G Magnet Asm, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Backing Plate, 

Deburred

$42.18 P.-P. Part G Magnet Asm, G Magnet Asm, Backing Plate, G Magnet Asm, 3.0000 sec 3.0000 sec - $0.04 1

Backing Plate, Stamped Backing Plate, 

Deburred Stamped

$42.18 Tool G Magnet Asm, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Backing Plate, 

Stamped

$42.18 Part G Magnet Asm, G Magnet Asm, Backing Plate, G Magnet Asm, 0.0000 sec 0.6000 sec $0.15 $0.01 1

Backing Plate, Material Backing Plate, 

Stamped Material

Design Profit ®

Page 51 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Blank weight 0.341 lbs - - - - - -

- - - Press Size 25 Ton Progressive - - - - - -

- - - Part Size after stamping (93 L by - - - - - -

84 W by 10 H)mm

$42.18 Operation G Magnet Asm, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Backing Plate, 

Deburred

$42.18 Material Mod. G Magnet Asm, Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.04 1

Backing Plate, 

Deburred

$42.18 Operation G Magnet Asm, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Backing Plate, 

Deburred

$20.81 Operation G Magnet Asm, Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 1

Backing Plate

$20.81 Operation G Magnet Asm, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.03 1

Backing Plate

$20.81 Operation G Magnet Asm, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Backing Plate

- - - weight of backing plate = 0.16 lb - - - - - -

$44.96 Tool G Magnet Asm, Clamp 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Weldment

$44.96 Fastening G Magnet Asm, Spot Weld 3.0000 sec 3.0000 sec $0.00 $0.04 6

Housing, 

Weldment

$44.96 Operation G Magnet Asm, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Weldment

$44.96 Operation G Magnet Asm, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Weldment

$10.75 Operation G Magnet Asm, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Housing, 

Weldment, 

Washed

$10.75 Operation G Magnet Asm, Wash Part Small 3.0000 sec 3.0000 sec $0.00 $0.01 1

Housing, 

Weldment, 

Washed

Design Profit ®

Page 52 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$10.75 Operation G Magnet Asm, Dry 3.0000 sec 3.0000 sec $0.00 $0.01 1

Housing, 

Weldment, 

Washed

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$29.69 Subassembly G Magnet Asm, G Magnet Asm, Coil w/connector G Magnet Asm, 3.0000 sec 3.0000 sec - $0.02 1

Potted Coil w/connector

$29.69 Tool G Magnet Asm, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Coil w/connector

$29.69 P.-P. Part G Magnet Asm, G Magnet Asm, Coil G Magnet Asm, 6.0000 sec 6.0000 sec - $0.05 1

Coil w/connector Coil

$29.69 Tool G Magnet Asm, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Coil

$29.69 Part G Magnet Asm, G Magnet Asm, Coil Material G Magnet Asm, 0.0000 sec 0.0000 sec $0.02 $0.00 351

Coil Coil Material

- - - Copper wire 0.8 mm (20 AWG), - - - - - -

wt=0.9 lb

$29.69 Operation G Magnet Asm, 18" Move 2.0000 sec 2.0000 sec $0.00 $0.02 1

Coil

Design Profit ®

Page 53 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$29.69 Material Mod. G Magnet Asm, Wind Coil - Medium 10.0000 sec 10.0000 sec $0.00 $0.08 1

Coil

$29.69 Operation G Magnet Asm, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Coil

$29.69 Part G Magnet Asm, Flux, Solder Flux, Solder 8.0000 sec 8.0000 sec $0.00 $0.07 1

Coil w/connector

$29.69 Tool G Magnet Asm, Solder Flux App Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Coil w/connector

$29.69 Tool G Magnet Asm, Soldering Tool 4.0000 sec 4.0000 sec $0.00 $0.03 1

Coil w/connector

$29.69 Subassembly G Magnet Asm, G Magnet Asm, Connector G Magnet Asm, 4.0000 sec 4.0000 sec $0.08 $0.03 1

Coil w/connector Connector

$29.69 Part G Magnet Asm, Solder Solder 2.0000 sec 2.0000 sec $0.00 $0.02 1

Coil w/connector

$16.39 P.-P. Part G Magnet Asm, G Magnet Asm, Liner G Magnet Asm, 0.0000 sec 0.8790 sec $0.02 $0.01 1

Potted Liner

- - - Plastic Liner weight required - - - - - -

= .023 lb

$29.69 Tool G Magnet Asm, Glue Bottle 3.0000 sec 3.0000 sec $0.00 $0.02 1

Potted

$29.69 Part G Magnet Asm, Adhesive, Liquid Adhesive, Liquid 6.0000 sec 6.0000 sec $0.00 $0.05 1

Potted

$29.69 Tool G Magnet Asm, Special Tool 6.0000 sec 6.0000 sec $0.00 $0.05 1

Potted

$29.69 Part G Magnet Asm, G Magnet Asm, Potting Material G Magnet Asm, 7.0000 sec 7.0000 sec $0.00 $0.06 1

Potted Potting Material

- - - Epoxy potting material - - - - - -

$29.69 Tool G Magnet Asm, Masking 3.0000 sec 3.0000 sec $0.00 $0.02 1

Potted

$29.69 Operation G Magnet Asm, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Potted

- - - Mask connector - - - - - -

$29.69 Operation G Magnet Asm, Mask Part - Simple 2.0000 sec 2.0000 sec $0.00 $0.02 1

Potted

$29.69 Tool G Magnet Asm, Spray Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Potted

$29.69 Part G Magnet Asm, Paint Paint 5.0000 sec 5.0000 sec $0.00 $0.04 1

Potted

$29.69 Material Mod. G Magnet Asm, Paint Part 3.3000 sec 3.3000 sec $0.00 $0.03 1

Potted

Design Profit ®

Page 54 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$29.69 Operation G Magnet Asm, Move 2.0000 sec 2.0000 sec $0.00 $0.02 1

Potted

- - - Air Dry Paint - - - - - -

$29.69 Operation G Magnet Asm, Remove Masking 2.0000 sec 2.0000 sec $0.00 $0.02 1

Potted

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 55 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$29.69 Subassembly G Magnet Asm., G Magnet Asm, Harness Pigtail G Magnet Asm, 4.0000 sec 4.0000 sec - $0.03 1

AC Clutch Harness Pigtail

$29.69 Tool G Magnet Asm, Special Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

Harness Pigtail

$29.69 Subassembly G Magnet Asm, G Magnet Asm, Pigtail Connector G Magnet Asm, 2.0000 sec 2.0000 sec $0.45 $0.02 1

Harness Pigtail 1 w/ overmolded wi Pigtail Connector 

1

$29.69 Subassembly G Magnet Asm, G magnet Asm, Pigtail Connector G magnet Asm, 7.0000 sec 7.0000 sec $0.20 $0.06 1

Harness Pigtail 2 Pigtail Connector 

2

$29.69 Fastening G Magnet Asm, Glue in Place 2.0000 sec 2.0000 sec $0.00 $0.02 1

Harness Pigtail

$29.69 Part G Magnet Asm, G Magnet Asm, Pigtail Connector G Magnet Asm, 6.0000 sec 6.0000 sec $0.03 $0.05 1

Harness Pigtail 2 Clip Pigtail Connector 

2 Clip

$29.69 Tool G Magnet Asm., Glue Bottle 3.0000 sec 3.0000 sec $0.00 $0.02 1

AC Clutch

$29.69 Part G Magnet Asm., Adhesive, Liquid Adhesive, Liquid 6.0000 sec 6.0000 sec $0.00 $0.05 1

AC Clutch

- - - spread glue on connector - - - - - -

- - - Attach pigtail connector to coil - - - - - -

connector

$29.69 Multitouch G Magnet Asm., G Magnet Asm, Potted G Magnet Asm, 5.0000 sec 5.0000 sec $0.00 $0.04 1

AC Clutch Potted

$29.69 Tool G Magnet Asm., Special Tool 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Clutch

- - - Swage tabs to lock pigtail - - - - - -

connector to housing

$29.69 Material Mod. G Magnet Asm., Swage 1.0000 sec 1.0000 sec $0.00 $0.01 1

AC Clutch

Design Profit ®

Page 56 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$35.51 Part G AC Systems G Snap-ring, AC Magnet G Snap-ring, AC 6.0000 sec 6.0000 sec $0.08 $0.06 1

Magnet

$35.51 Operation G AC Systems CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

$35.51 Tool G AC Systems Special Tool 6.0000 sec 6.0000 sec $0.00 $0.06 1

$35.51 Fastening G AC Systems Position Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

$35.51 Operation G AC Systems CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 57 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 58 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$35.51 Subassembly Subassembly G AC Systems G AC Systems G Clutch Pully Asm G Clutch Pully Asm G Clutch Pully G Clutch Pully 6.0000 sec 6.0000 sec 6.0000 sec 6.0000 sec - $0.06 1

Asm

$35.51 Tool G Clutch Pully First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm

$43.52 P.-P. Part G Clutch Pully G Clutch Pulley, Machined Final G Clutch Pulley, 4.0000 sec 4.0000 sec - $0.04 1

Asm Machined Final

- - - "CNC Mach, Auto Sml Size - - - - - -

and/or Low Complexity"

- - - Pallet Size 300 mm square, 550 - - - - - -

lb Capacity

$43.52 P.-P. Part G Clutch Pulley, G Clutch Pulley, Paint G Clutch Pulley, 6.0000 sec 6.0000 sec - $0.07 1

Machined Final Paint

$10.75 P.-P. Part G Clutch Pulley, G Clutch Pulley, Washed G Clutch Pulley, 5.0000 sec 5.0000 sec - $0.06 1

Paint Washed

- - - "Washing, Small Size and/or Low - - - - - -

Complexity"

$10.75 Tool G Clutch Pulley, Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Washed DRY

Design Profit ®

Page 59 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 P.-P. Part G Clutch Pulley, G Clutch Pulley, Machined G Clutch Pulley, 3.0000 sec 3.0000 sec - $0.01 1

Washed Machined

- - - "CNC Mach, Auto Sml Size - - - - - -

and/or Low Complexity"

- - - Pallet Size 300 mm square, 550 - - - - - -

lb Capacity

$43.52 P.-P. Part G Clutch Pulley, G Clutch Pulley, Trimmed G Clutch Pulley, 5.0000 sec 5.0000 sec - $0.06 1

Machined Trimmed

$43.52 Tool G Clutch Pulley, Trim Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Trimmed

- - - Analysis complete - 1/29/10 - DO - - - - - -

$43.52 P.-P. Part G Clutch Pulley, G Clutch Pulley w/gates and G Clutch Pulley 0.0000 sec 0.0000 sec - $0.00 1

Trimmed runners w/gates and 

runners

$43.52 Tool G Clutch Pulley First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

w/gates and 

runners

$43.52 P.-P. Part G Clutch Pulley G Clutch Pulley, Sand Cast G Clutch Pulley, 5.0000 sec 5.0000 sec - $0.06 1

w/gates and Sand Cast

runners

$43.52 Tool G Clutch Pulley, Mold Making DISA 240 w/100 m 0.0000 sec 0.0000 sec $0.00 $0.00 1

Sand Cast Cooling Line

$43.52 Part G Clutch Pulley, G Clutch Pulley, Steel Mtl G Clutch Pulley, 0.0000 sec 0.0000 sec $1.00 $0.00 1

Sand Cast Steel Mtl

- - - 6 Cavities (3x2) of 2.38 lb per - - - - - -

part @$.42 per lb

$43.52 Part G Clutch Pulley, G Clutch Pulley Casting Energy G Clutch Pulley 0.0000 sec 0.0000 sec $0.27 $0.00 1

Sand Cast Casting Energy

$43.52 Part G Clutch Pulley, G Clutch Pulley Mold Sand Lost G Clutch Pulley 0.0000 sec 1.3300 sec $0.16 $0.02 1

Sand Cast Mold Sand Lost

$43.52 Operation G Clutch Pulley Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

w/gates and 

runners

$43.52 Material Mod. G Clutch Pulley Remove Mold Sand No Cores 5.0000 sec 5.0000 sec $0.00 $0.06 1

w/gates and 

runners

$43.52 Operation G Clutch Pulley Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

w/gates and 

runners

$43.52 Operation G Clutch Pulley, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Trimmed

Design Profit ®

Page 60 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$43.52 Operation G Clutch Pulley, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Trimmed

$43.52 Material Mod. G Clutch Pulley, Trim Flash/Gates 3.0000 sec 3.0000 sec $0.00 $0.04 1

Trimmed

$43.52 Operation G Clutch Pulley, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Trimmed

$43.52 Operation G Clutch Pulley, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Trimmed

$41.20 Tool G Clutch Pulley, EC-300-AL Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 1

Machined Machine

$41.20 Operation G Clutch Pulley, Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Machined

$41.20 Operation G Clutch Pulley, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Machined

- - - FRONT FACE - - - - - -

$41.20 Material Mod. G Clutch Pulley, Turn End Face 60-100mm 6.0000 sec 6.0000 sec $0.00 $0.07 1

Machined

$41.20 Operation G Clutch Pulley, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

- - - OUTER DIAMETER - - - - - -

$41.20 Material Mod. G Clutch Pulley, Turn OD Med 60-100mm 3.0000 sec 3.0000 sec $0.00 $0.03 1

Machined

$41.20 Operation G Clutch Pulley, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

- - - CUT BELT GROVES - - - - - -

$41.20 Material Mod. G Clutch Pulley, Turn OD Contoured surface fins 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Operation G Clutch Pulley, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

- - - INSIDE POCKET BORE - - - - - -

$41.20 Material Mod. G Clutch Pulley, Bore Hole 100-150mm dia 4.0000 sec 4.0000 sec $0.00 $0.05 1

Machined

$41.20 Operation G Clutch Pulley, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Material Mod. G Clutch Pulley, Bore Hole 60-100mm 3.0000 sec 3.0000 sec $0.00 $0.03 1

Machined

$41.20 Operation G Clutch Pulley, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Material Mod. G Clutch Pulley, Turn End Face 60-100mm 6.0000 sec 6.0000 sec $0.00 $0.07 1

Machined

Design Profit ®

Page 61 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$41.20 Operation G Clutch Pulley, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

- - - SHAFT HOLE - - - - - -

$41.20 Material Mod. G Clutch Pulley, Drill Hole 30 - 60mm 2.0000 sec 2.0000 sec $0.00 $0.02 1

Machined

$41.20 Operation G Clutch Pulley, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Material Mod. G Clutch Pulley, Bore Hole 60-100mm 3.0000 sec 3.0000 sec $0.00 $0.03 1

Machined

- - - SLOTS - - - - - -

$41.20 Operation G Clutch Pulley, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined

$41.20 Material Mod. G Clutch Pulley, End Mill Slot Cut 1.0000 sec 1.0000 sec $0.00 $0.01 4

Machined

$41.20 Operation G Clutch Pulley, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Machined

$41.20 Material Mod. G Clutch Pulley, End Mill Slot Cut 1.0000 sec 1.0000 sec $0.00 $0.01 6

Machined

$41.20 Operation G Clutch Pulley, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 5

Machined

$41.20 Operation G Clutch Pulley, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Machined

$41.20 Operation G Clutch Pulley, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Machined

- - - Batch Type Washer - - - - - -

- - - 5-10 min cycle time - - - - - -

- - - Basket Size 15.75x18.50x25.50 - - - - - -

inches x 2

$10.75 Operation G Clutch Pulley, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Washed

$10.75 Operation G Clutch Pulley, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 1

Washed

$10.75 Operation G Clutch Pulley, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Washed

$43.52 Operation G Clutch Pulley, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Paint

$43.52 Material Mod. G Clutch Pulley, Paint Part 1.6000 sec 1.6000 sec $0.00 $0.02 1

Paint

$43.52 Operation G Clutch Pulley, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Paint

Design Profit ®

Page 62 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$43.52 Operation G Clutch Pulley, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Machined Final

$43.52 Operation G Clutch Pulley, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Machined Final

- - - BACK FACE - - - - - -

$43.52 Material Mod. G Clutch Pulley, Turn End Face 60-100mm 6.0000 sec 6.0000 sec $0.00 $0.07 1

Machined Final

$43.52 Operation G Clutch Pulley, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Machined Final

$43.52 Operation G Clutch Pulley, Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.04 1

Machined Final

$43.52 Operation G Clutch Pulley, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Machined Final

- - - SHAFT HOLE - - - - - -

$43.52 Operation G Clutch Pulley, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 1

Machined Final

$43.52 Material Mod. G Clutch Pulley, Hone Hole 2 inch depth 3.0000 sec 3.0000 sec $0.00 $0.04 1

Machined Final

$43.52 Operation G Clutch Pulley, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Machined Final

$43.52 Operation G Clutch Pulley, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Machined Final

$35.51 Part G Clutch Pully G Clutch Pully, Friction Material G Clutch Pully, 5.0000 sec 5.0000 sec $0.00 $0.05 1

Asm Friction Material

$35.51 Tool G Clutch Pully Glue Bottle 3.0000 sec 3.0000 sec $0.00 $0.03 1

Asm

$35.51 Fastening G Clutch Pully Glue in Place 2.0000 sec 2.0000 sec $0.00 $0.02 1

Asm

$35.51 Operation G Clutch Pully Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 1

Asm

$0.00 Subassembly G Clutch Pully G Clutch Pulley, Bearing G Clutch Pulley, 6.0000 sec 6.0000 sec $1.51 $0.06 1

Asm Bearing

$35.51 Tool G Clutch Pully Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm

$35.51 Fastening G Clutch Pully Press Together 3.0000 sec 3.0000 sec $0.00 $0.03 1

Asm

$35.51 Tool G Clutch Pully Stamping Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm

$35.51 Operation G Clutch Pully Change Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Asm

Design Profit ®

Page 63 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$35.51 Material Mod. G Clutch Pully Swage 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm

$35.51 Operation G AC Systems CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

$35.51 Part G AC Systems G Snap-ring, AC Hub G Snap-ring, AC 6.0000 sec 6.0000 sec $0.08 $0.06 1

Hub

$35.51 Tool G AC Systems Special Tool 6.0000 sec 6.0000 sec $0.00 $0.06 1

$35.51 Fastening G AC Systems Position Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

$35.51 Operation G AC Systems CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

- - - ** DWarner ** Complete to End - - - - - -

$35.51 Part G AC Systems G Shim, Clutch Hub G Shim, Clutch 6.0000 sec 6.0000 sec $0.01 $0.06 2

Hub

$35.51 Fastening G AC Systems Set In Place 1.0000 sec 1.0000 sec $0.00 $0.01 2

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 64 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$35.51 Subassembly G AC Systems G Clutch Hub Asm G Clutch Hub 6.0000 sec 6.0000 sec - $0.06 1

Asm

$35.51 Tool G Clutch Hub First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Asm

$35.51 Part G Clutch Hub G Clutch Hub, Rivet Pin, M5 G Clutch Hub, 3.0000 sec 3.0000 sec $0.02 $0.03 3

Asm Rivet Pin, M5

$42.18 P.-P. Part G Clutch Hub G Clutch Hub, Isolator, Painted G Clutch Hub, 6.0000 sec 6.0000 sec - $0.06 1

Asm Asm Isolator, Painted 

Asm

$42.18 Tool G Clutch Hub, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Painted 

Asm

- - - Spray - - - - - -

$16.39 P.-P. Part G Clutch Hub, G Clutch Hub, Isolator, Insert G Clutch Hub, 3.0000 sec 3.0000 sec - $0.04 1

Isolator, Painted Molded Asm Isolator, Insert 

Asm Molded Asm

$16.39 Tool G Clutch Hub, Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Insert ton

Molded Asm

$20.81 P.-P. Part G Clutch Hub, G Clutch Hub, Isolator, Inner, G Clutch Hub, 3.0000 sec 3.0000 sec - $0.01 1

Isolator, Insert Washed Isolator, Inner, 

Molded Asm Washed

$20.81 Tool G Clutch Hub, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Inner, 

Washed

$42.18 P.-P. Part G Clutch Hub, G Clutch Hub, Isolator, Inner, G Clutch Hub, 3.0000 sec 3.0000 sec - $0.02 1

Isolator, Inner, Deburred Isolator, Inner, 

Washed Deburred

Design Profit ®

Page 65 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$42.18 Tool G Clutch Hub, Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Inner, 

Deburred

$19.15 P.-P. Part G Clutch Hub, G Clutch Hub, Isolator, Inner, G Clutch Hub, 3.0000 sec 3.0000 sec - $0.04 1

Isolator, Inner, Machined Isolator, Inner, 

Deburred Machined

$19.15 Tool G Clutch Hub, CNC Turning 2 Axis SL-10, Odd 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Inner, Form

Machined

$15.50 P.-P. Part G Clutch Hub, G Clutch Hub, Isolator, Inner, G Clutch Hub, 3.0000 sec 3.0000 sec - $0.02 1

Isolator, Inner, Stamped Isolator, Inner, 

Machined Stamped

$15.50 Tool G Clutch Hub, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Inner, 

Stamped

$15.50 Part G Clutch Hub, G Clutch Hub, Isolator, Inner, G Clutch Hub, 0.0000 sec 0.7000 sec $0.13 $0.00 1

Isolator, Inner, Stell Isolator, Inner, 

Stamped Steel

- - - Blank weight 0.242 lbs - - - - - -

- - - Press Size 60 Ton, Progressive - - - - - -

- - - Part Size (60.2mm Diam by - - - - - -

12.2mm H)

$19.15 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 1

Isolator, Inner, 

Machined

$19.15 Operation G Clutch Hub, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.02 1

Isolator, Inner, 

Machined

$19.15 Material Mod. G Clutch Hub, Turn End face 1-30mm 2.0000 sec 2.0000 sec $0.00 $0.01 1

Isolator, Inner, 

Machined

$19.15 Operation G Clutch Hub, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 1

Isolator, Inner, 

Machined

- - - Combo Tool Used: Drill & Tap - - - - - -

$19.15 Material Mod. G Clutch Hub, Drill and Tap Hole 1-30mm 5.0000 sec 5.0000 sec $0.00 $0.03 3

Isolator, Inner, 

Machined

$19.15 Operation G Clutch Hub, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 2

Isolator, Inner, 

Machined

Design Profit ®

Page 66 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$19.15 Operation G Clutch Hub, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Isolator, Inner, 

Machined

$19.15 Operation G Clutch Hub, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Isolator, Inner, 

Machined

- - - Batch - - - - - -

$42.18 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Isolator, Inner, 

Deburred

$42.18 Material Mod. G Clutch Hub, Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.04 1

Isolator, Inner, 

Deburred

$42.18 Operation G Clutch Hub, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Isolator, Inner, 

Deburred

- - - In-Line Washer - - - - - -

$20.81 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 1

Isolator, Inner, 

Washed

$20.81 Operation G Clutch Hub, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.03 1

Isolator, Inner, 

Washed

$20.81 Operation G Clutch Hub, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Isolator, Inner, 

Washed

$16.39 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Isolator, Insert 

Molded Asm

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$20.81 P.-P. Part G Clutch Hub, G Clutch Hub, Isolator, Outer, G Clutch Hub, 5.0000 sec 5.0000 sec - $0.02 1

Isolator, Insert Washed Isolator, Outer, 

Molded Asm Washed

$20.81 Tool G Clutch Hub, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Outer, 

Washed

Design Profit ®

Page 67 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$42.18 P.-P. Part G Clutch Hub, G Clutch Hub, Isolator, Outer, G Clutch Hub, 3.0000 sec 3.0000 sec - $0.02 1

Isolator, Outer, Deburred Isolator, Outer, 

Washed Deburred

$42.18 Tool G Clutch Hub, Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Outer, 

Deburred

$15.50 P.-P. Part G Clutch Hub, G Clutch Hub, Isolator, Outer, G Clutch Hub, 3.0000 sec 3.0000 sec - $0.04 1

Isolator, Outer, Stamped Isolator, Outer, 

Deburred Stamped

$15.50 Tool G Clutch Hub, Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Outer, 

Stamped

$15.50 Part G Clutch Hub, G Clutch Hub, Isolator, Outer, G Clutch Hub, 0.0000 sec 0.7000 sec $0.17 $0.00 1

Isolator, Outer, Steel Isolator, Outer, 

Stamped Steel

- - - Blank weight 0.307 lbs - - - - - -

- - - Press Size 60 Ton, Progressive - - - - - -

- - - Part Size (100mm Diam by 13mm - - - - - -

H)

- - - Batch - - - - - -

$42.18 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Isolator, Outer, 

Deburred

$42.18 Material Mod. G Clutch Hub, Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.04 1

Isolator, Outer, 

Deburred

$42.18 Operation G Clutch Hub, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Isolator, Outer, 

Deburred

- - - In-Line Washer - - - - - -

$20.81 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 1

Isolator, Outer, 

Washed

$20.81 Operation G Clutch Hub, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.03 1

Isolator, Outer, 

Washed

$20.81 Operation G Clutch Hub, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Isolator, Outer, 

Washed

$16.39 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 1

Isolator, Insert 

Molded Asm

Design Profit ®

Page 68 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$16.39 Part G Clutch Hub, G Clutch Hub, Isolator, SBR G Clutch Hub, 0.0000 sec 33.0300 sec $0.09 $0.15 1

Isolator, Insert Isolator, SBR

Molded Asm

$16.39 Operation G Clutch Hub, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Isolator, Insert 

Molded Asm

- - - Raw Material Req 0.081 lbs - - - - - -

- - - 6 Cavity Mold - - - - - -

- - - Box Size 83mm Diam x 13mm H - - - - - -

$42.18 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Isolator, Painted 

Asm

$42.18 Operation G Clutch Hub, Paint Part Small 3.0000 sec 3.0000 sec $0.00 $0.04 1

Isolator, Painted 

Asm

$42.18 Tool G Clutch Hub, Oven 0.0000 sec 0.0000 sec $0.00 $0.00 1

Isolator, Painted 

Asm

- - - This Oven time is for a small - - - - - -

Batch part

$42.18 Operation G Clutch Hub, Paint Oven Cure 60.0000 sec 60.0000 sec $0.00 $0.70 1

Isolator, Painted 

Asm

$42.18 Operation G Clutch Hub, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Isolator, Painted 

Asm

$35.51 Part G Clutch Hub G Clutch Hub, Washer, M5 G Clutch Hub, 4.0000 sec 4.0000 sec $0.01 $0.04 3

Asm Washer, M5

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 69 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$42.18 P.-P. Part G Clutch Hub G Clutch Hub, Face G Clutch Hub, 3.0000 sec 3.0000 sec - $0.03 1

Asm Face

$42.18 Tool G Clutch Hub, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Face

- - - Spray - - - - - -

$20.81 P.-P. Part G Clutch Hub, G Clutch Hub, Face, Washed G Clutch Hub, 3.0000 sec 3.0000 sec - $0.04 1

Face Face, Washed

$20.81 Tool G Clutch Hub, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Face, Washed

$42.18 P.-P. Part G Clutch Hub, G Clutch Hub, Face, Deburred G Clutch Hub, 3.0000 sec 3.0000 sec - $0.02 1

Face, Washed Face, Deburred

$42.18 Tool G Clutch Hub, Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Face, Deburred

$19.15 P.-P. Part G Clutch Hub, G Clutch Hub, Face, Machined G Clutch Hub, 3.0000 sec 3.0000 sec - $0.04 1

Face, Deburred Face, Deburred-1

$19.15 Tool G Clutch Hub, CNC Turning 2 Axis SL-10, Odd 0.0000 sec 0.0000 sec $0.00 $0.00 1

Face, Machined Form

$42.91 P.-P. Part G Clutch Hub, G Clutch Hub, Face, Stamped G Clutch Hub, 3.0000 sec 3.0000 sec - $0.02 1

Face, Machined Face, Stamped

$42.91 Tool G Clutch Hub, G Clutch Hub, Stamping Press 200-400 Ton Stamping Press 200-400 Ton 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 1

Face, Stamped

$42.91 Part G Clutch Hub, G Clutch Hub, Face, Steel G Clutch Hub, 0.0000 sec 2.0000 sec $0.64 $0.02 1

Face, Stamped Face, Steel

- - - Blank weight 1.167 lbs - - - - - -

- - - Press Size 400 Ton Progressive - - - - - -

- - - Part Size 108 mm Diam by - - - - - -

4.7mm H

$19.15 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 1

Face, Machined

$19.15 Operation G Clutch Hub, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.02 1

Face, Machined

$19.15 Material Mod. G Clutch Hub, Turn End face 1-30mm 2.0000 sec 2.0000 sec $0.00 $0.01 1

Face, Machined

$19.15 Operation G Clutch Hub, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 1

Face, Machined

- - - Counterbore Rivit Relief - - - - - -

$19.15 Material Mod. G Clutch Hub, Counter Bore Hole Small 1.0000 sec 1.0000 sec $0.00 $0.01 3

Face, Machined

Design Profit ®

Page 70 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$19.15 Operation G Clutch Hub, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 2

Face, Machined

$19.15 Operation G Clutch Hub, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Face, Machined

$19.15 Operation G Clutch Hub, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Face, Machined

- - - Batch - - - - - -

$42.18 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Face, Deburred

$42.18 Material Mod. G Clutch Hub, Debur/Tumble 3.0000 sec 3.0000 sec $0.00 $0.04 1

Face, Deburred

$42.18 Operation G Clutch Hub, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Face, Deburred

- - - In-Line Washer - - - - - -

$20.81 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 1

Face, Washed

$20.81 Operation G Clutch Hub, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.03 1

Face, Washed

$20.81 Operation G Clutch Hub, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Face, Washed

$42.18 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Face

$42.18 Operation G Clutch Hub, Paint Part Small 3.0000 sec 3.0000 sec $0.00 $0.04 1

Face

$42.18 Tool G Clutch Hub, Oven 0.0000 sec 0.0000 sec $0.00 $0.00 1

Face

- - - This Oven time is for a small - - - - - -

Batch part

$42.18 Operation G Clutch Hub, Paint Oven Cure 60.0000 sec 60.0000 sec $0.00 $0.70 1

Face

$42.18 Operation G Clutch Hub, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Face

- - - 3 Rivets Swaged at Once - - - - - -

$35.51 Material Mod. G Clutch Hub Swage 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 71 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$37.60 P.-P. Part G Clutch Hub G Clutch Hub, Splined Hub, G Clutch Hub, 6.0000 sec 6.0000 sec - $0.06 1

Asm Painted Splined Hub, 

Painted

$37.60 Tool G Clutch Hub, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Splined Hub, 

Painted

- - - Spray - - - - - -

$20.81 P.-P. Part G Clutch Hub, G Clutch Hub, Splined Hub, G Clutch Hub, 3.0000 sec 3.0000 sec - $0.03 1

Splined Hub, Washed Splined Hub, 

Painted Washed

$20.81 Tool G Clutch Hub, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Splined Hub, 

Washed

$37.60 P.-P. Part G Clutch Hub, G Clutch Hub, Splined Hub, G Clutch Hub, 3.0000 sec 3.0000 sec - $0.02 1

Splined Hub, Broached Splined Hub, 

Washed Broached

$37.60 Tool G Clutch Hub, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Splined Hub, 

Broached

$30.84 P.-P. Part G Clutch Hub, G Clutch Hub, Splined Hub, CNC G Clutch Hub, 3.0000 sec 3.0000 sec - $0.03 1

Splined Hub, Turned Splined Hub, 

Broached CNC Turned

$30.84 Tool G Clutch Hub, CNC Turning 4 Axis SL-10, 1.75 0.0000 sec 0.0000 sec $0.00 $0.00 1

Splined Hub, bar

CNC Turned

- - - Includes Bar Feeder - - - - - -

$30.84 Part G Clutch Hub, G Clutch Hub, Center Hub, G Clutch Hub, 3.0000 sec 3.0000 sec $0.39 $0.03 1

Splined Hub, Splined, Steel Bar Center Hub, 

CNC Turned Splined, Steel 

Bar

- - - Bar Stock, 45mm Diam x 19mm - - - - - -

H, 0.523 LB

- - - Finished Part, 45mm Diam x - - - - - -

179mm H

- - - Machine Part to Part Mating Face - - - - - -

Design Profit ®

Page 72 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$30.84 Material Mod. G Clutch Hub, Turn end face 1-30mm 2.0000 sec 2.0000 sec $0.00 $0.02 1

Splined Hub, 

CNC Turned

- - - Drill Shaft Mating Hole - - - - - -

$30.84 Operation G Clutch Hub, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

Splined Hub, 

CNC Turned

$30.84 Material Mod. G Clutch Hub, Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Splined Hub, 

CNC Turned

- - - Drill 3 M6 Holes - - - - - -

$30.84 Operation G Clutch Hub, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

Splined Hub, 

CNC Turned

$30.84 Material Mod. G Clutch Hub, Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 3

Splined Hub, 

CNC Turned

$30.84 Operation G Clutch Hub, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 2

Splined Hub, 

CNC Turned

- - - Drill 3 3.75mm Holes - - - - - -

$30.84 Operation Operation G Clutch Hub, G Clutch Hub, Auto Tool Change Auto Tool Change 5.0000 sec 5.0000 sec 5.0000 sec 5.0000 sec $0.00 $0.04 1

Splined Hub, 

CNC Turned

$30.84 Material Mod. G Clutch Hub, Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 3

Splined Hub, 

CNC Turned

$30.84 Operation G Clutch Hub, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 2

Splined Hub, 

CNC Turned

- - - Machine Shaft Hub Portion - - - - - -

$30.84 Operation G Clutch Hub, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

Splined Hub, 

CNC Turned

$30.84 Material Mod. G Clutch Hub, Turn End face 1-30mm 2.0000 sec 2.0000 sec $0.00 $0.02 1

Splined Hub, 

CNC Turned

$30.84 Operation G Clutch Hub, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Splined Hub, 

CNC Turned

Design Profit ®

Page 73 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$30.84 Material Mod. G Clutch Hub, Turn End face 1-30mm 2.0000 sec 2.0000 sec $0.00 $0.02 1

Splined Hub, 

CNC Turned

- - - Cut Piece from Bar with Parting - - - - - -

Tool 

- - - Grab Turned Piece with 2nd - - - - - -

Chuck Head

$30.84 Operation G Clutch Hub, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

Splined Hub, 

CNC Turned

$30.84 Material Mod. G Clutch Hub, Turn End face 1-30mm 2.0000 sec 2.0000 sec $0.00 $0.02 1

Splined Hub, 

CNC Turned

$30.84 Operation G Clutch Hub, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Splined Hub, 

CNC Turned

- - - Chamfer Hub at Parting Area - - - - - -

$30.84 Operation G Clutch Hub, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

Splined Hub, 

CNC Turned

$30.84 Material Mod. G Clutch Hub, Turn End face 1-30mm 2.0000 sec 2.0000 sec $0.00 $0.02 1

Splined Hub, 

CNC Turned

$30.84 Operation G Clutch Hub, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Splined Hub, 

CNC Turned

$30.84 Material Mod. G Clutch Hub, Turn End face 1-30mm 2.0000 sec 2.0000 sec $0.00 $0.02 1

Splined Hub, 

CNC Turned

$30.84 Operation G Clutch Hub, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Splined Hub, 

CNC Turned

$37.60 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Splined Hub, 

Broached

$37.60 Operation G Clutch Hub, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Splined Hub, 

Broached

$37.60 Material Mod. G Clutch Hub, Broach Steel 1 ft lng tool 1.5000 sec 1.5000 sec $0.00 $0.02 1

Splined Hub, 

Broached

Design Profit ®

Page 74 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$37.60 Operation G Clutch Hub, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Splined Hub, 

Broached

$37.60 Operation G Clutch Hub, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Splined Hub, 

Broached

- - - In-Line Washer - - - - - -

$20.81 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 1

Splined Hub, 

Washed

$20.81 Operation G Clutch Hub, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.03 1

Splined Hub, 

Washed

$20.81 Operation G Clutch Hub, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Splined Hub, 

Washed

$37.60 Operation G Clutch Hub, Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Splined Hub, 

Painted

$37.60 Operation G Clutch Hub, Paint Part Small 3.0000 sec 3.0000 sec $0.00 $0.03 1

Splined Hub, 

Painted

$37.60 Tool G Clutch Hub, Oven 0.0000 sec 0.0000 sec $0.00 $0.00 1

Splined Hub, 

Painted

- - - This Oven time is for a small - - - - - -

Batch part

$37.60 Operation G Clutch Hub, Paint Oven Cure 60.0000 sec 60.0000 sec $0.00 $0.63 1

Splined Hub, 

Painted

$37.60 Operation G Clutch Hub, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Splined Hub, 

Painted

$35.51 Operation G Clutch Hub Align to Base 2.0000 sec 2.0000 sec $0.00 $0.02 1

Asm

$35.51 Part G Clutch Hub G Clutch Hub, Rivet Pin, M6 G Clutch Hub, 7.0000 sec 7.0000 sec $0.02 $0.07 3

Asm Rivet Pin, M6

- - - 3 Rivets Swaged at Once - - - - - -

$35.51 Material Mod. G Clutch Hub Swage 1.0000 sec 1.0000 sec $0.00 $0.01 1

Asm

$35.51 Fastening G AC Systems Set In Place 1.0000 sec 1.0000 sec $0.00 $0.01 1

Design Profit ®

Page 75 of #
Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$35.51 Part G AC Systems G Bolt, Clutch Hub G Bolt, Clutch 6.0000 sec 6.0000 sec $0.02 $0.06 1

Hub

$35.51 Tool G AC Systems Power Tool 4.0000 sec 4.0000 sec $0.00 $0.04 1

$35.51 Fastening G AC Systems Power Screw 4.0000 sec 4.0000 sec $0.00 $0.04 1

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 76 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$50.58 P.-P. Part G AC Systems G Clutch Hub, Cover, Molded G Clutch Hub, 6.0000 sec 6.0000 sec - $0.06 1

Cover, Molded

$50.58 Tool G Clutch Hub, Inj Molding Machine 400-800 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover, Molded

$50.58 Part G Clutch Hub, G Clutch Hub, Cover, Material G Clutch Hub, 0.0000 sec 3.4560 sec $0.21 $0.05 1

Cover, Molded Cover, Material

- - - Raw Material Req 0.147 lbs - - - - - -

- - - 6 Cavity Mold - - - - - -

- - - Box Size 120mm Dia x 23mm H - - - - - -

$35.51 Fastening G AC Systems Set In Place 1.0000 sec 1.0000 sec $0.00 $0.01 1

$35.51 Part G AC Systems G Bolt, AC Clutch Hub Cover G Bolt, AC Clutch 6.0000 sec 6.0000 sec $0.01 $0.06 3

Hub Cover

$35.51 Tool G AC Systems 3 Spindle Nut Runner 6.0000 sec 6.0000 sec $0.00 $0.06 1

$35.51 Fastening G AC Systems Power Screw 4.0000 sec 4.0000 sec $0.00 $0.04 1

$35.51 Operation G AC Systems CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

$55.17 P.-P. Part G AC Systems G Bracket, AC Electrical, Zinc G Bracket, AC 7.0000 sec 7.0000 sec - $0.07 1

Plated Electrical, Zinc 

Plated

$55.17 Tool G Bracket, AC Anodizing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 1

Electrical, Zinc 

Plated

- - - Zinc Plating, Batched Processed - - - - - -

$20.81 P.-P. Part G Bracket, AC G Bracket, AC Electrical, Washed G Bracket, AC 3.0000 sec 3.0000 sec - $0.05 1

Electrical, Zinc Electrical, 

Plated Washed

$20.81 Tool G Bracket, AC Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Electrical, 

Washed

$15.50 P.-P. Part G Bracket, AC G Bracket, AC Electrical, G Bracket, AC 3.0000 sec 3.0000 sec - $0.02 1

Electrical, Stamped Electrical, 

Washed Stamped

$15.50 Tool G Bracket, AC Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Electrical, 

Stamped

$15.50 Part G Bracket, AC G Bracket, AC Electrical, Steel G Bracket, AC 0.0000 sec 0.6000 sec $0.01 $0.00 1

Electrical, Electrical, Steel

Stamped

- - - Blank weight 0.016 lbs - - - - - -

- - - Press Size 25 Ton, Progressive - - - - - -

Design Profit ®

Page 77 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - Part Size (37.8mm L, 23.4mm W, - - - - - -

1.44mm H)

- - - In-Line Washer - - - - - -

$20.81 Operation G Bracket, AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 1

Electrical, 

Washed

$20.81 Operation G Bracket, AC Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.03 1

Electrical, 

Washed

$20.81 Operation G Bracket, AC Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Electrical, 

Washed

$55.17 Operation G Bracket, AC Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

Electrical, Zinc 

Plated

$55.17 Operation G Bracket, AC Electroplate Process 0.4176 sec 1.8156 sec $0.00 $0.03 1

Electrical, Zinc 

Plated

- - - Surface area to Plate: 1.38 Sq - - - - - -

Inches $0.17

$55.17 Operation G Bracket, AC Remove Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Electrical, Zinc 

Plated

$35.51 Part G AC Systems G Bolt, Bracket, AC Electrical G Bolt, Bracket, 6.0000 sec 6.0000 sec $0.01 $0.06 1

AC Electrical

$35.51 Tool G AC Systems Power Tool 4.0000 sec 4.0000 sec $0.00 $0.04 1

$35.51 Fastening G AC Systems Power Screw 4.0000 sec 4.0000 sec $0.00 $0.04 1

- - - Analysis here to end complete - - - - - - -

DO - 1/27/10

$83.31 Operation G AC Systems CDI 1.0000 sec 1.0000 sec $0.00 $0.02 1

$83.31 Part G AC Systems G Bolt, Short, AC Asm to Hoses G Bolt, Short, AC 6.0000 sec 6.0000 sec $0.06 $0.14 1

Asm to Hoses

$83.31 Tool G AC Systems Power Tool 4.0000 sec 4.0000 sec $0.00 $0.09 1

$83.31 Fastening G AC Systems Power Screw 4.0000 sec 4.0000 sec $0.00 $0.09 1

$83.31 Operation G AC Systems CDI 1.0000 sec 1.0000 sec $0.00 $0.02 1

$83.31 Part G AC Systems G Bolt, Long, AC Asm. to Bracket G Bolt, Long, AC 6.0000 sec 6.0000 sec $0.22 $0.14 1

Asm. to Bracket

$83.31 Tool G AC Systems Power Tool 4.0000 sec 4.0000 sec $0.00 $0.09 1

$83.31 Fastening G AC Systems Power Screw 4.0000 sec 4.0000 sec $0.00 $0.09 1

Design Profit ®

Page 78 of #

Copyright 2005© Munro & Associates, Inc.
G AC Systems

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

Report Totals Count: ##

1,780

Design Profit ®

Page 79 of #

Copyright 2005© Munro & Associates, Inc.
Piece Cost 

(Total)

$0.00

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

-

-

$0.00

-
Piece Cost 

(Total)

$0.00

$0.99

-

-

-

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$0.00

$0.00

$0.00

-

-

-

$0.55

$0.00

$0.00

$0.00

$0.00

$0.06

$0.00

$0.00

$0.00

$0.06

$0.00

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$0.00

$0.10

$0.00

$0.00

$0.11

$0.00

$0.17

$0.00

$0.12

$0.00

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

Piece Cost 

(Total)

$0.70

-

-

$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

-
Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$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

-

-

-

-

-

-
Piece Cost 

(Total)

-

-

-

-

-

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

$0.00

$1.08

-

-

-

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

Piece Cost 

(Total)

-

-

-

-

-

-

-

$0.00

$0.27

-

-

-

$0.00

$0.00

$0.00

$0.00

$0.11

$0.00

$0.17

$0.00

$0.12

$0.00

-

Piece Cost 

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Cost 

(Total)

-

-

-

-

-

-

-

-

-

-

-

$0.00

$0.05

-

-

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

Piece Cost 

(Total)

-

$0.00

-

-

$0.00

$2.05

-

-

-

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$0.00

$0.00

$0.00

-

-

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.00

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

$0.55

$0.00

$0.00

Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.06

$0.00

$0.00

$0.00

$0.00

$0.00

$0.10

$0.00

$0.00

$0.11

$0.00

$0.00

-

-

-

Piece Cost 

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Cost 

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Cost 

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

$0.00

-

-

-

$0.00

-

$0.00

$0.03

-

-

-

Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

-

$0.00

-

-

$0.00

-

-

$0.00

-

Piece Cost 

(Total)

$0.00

$0.30

-

-

-

$0.00

$0.00

-

$0.00

-

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$0.00

$0.00

-

-

-

$0.00

-

-

-

-

-

-

$0.00

-

-

$0.00

-

$0.00

$0.02

-

-

-

$0.00

$0.00

$0.00
Piece Cost 

(Total)

-

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

-

$0.00

-

-

$0.00

-

$0.00

$0.04

-

-

$0.00

$0.00

$0.00

-
Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.00

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Cost 

(Total)

-

-

-

-

$0.00

$0.04

-

-

$0.00

-

$0.00

-

$0.00

-

-

-

$0.00

-

-

-

$0.00

-

-
Piece Cost 

(Total)

$0.00

$0.86

-

-

-

$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

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$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

-

-

-

$0.28

Piece Cost 

(Total)

$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

-

Piece Cost 

(Total)

$0.00

$0.04

-

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

-

-

-

-

-
Piece Cost 

(Total)

$0.00

-

$0.00

-

$0.00

-

$0.00

$0.30

-

-

-

$0.00

$0.00

-

$0.00

-

$0.00

Piece Cost 

(Total)

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

$0.00

-

-

-

-

-

-

-

-

-

-

-

Piece Cost 

(Total)

-

-

$0.00

-

-

$0.00

-

$0.00

$0.02

-

-

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-
Piece Cost 

(Total)

-

-

-

$0.00

-

-

$0.00

-

$0.00

$0.04

-

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

Piece Cost 

(Total)

$0.00

-

$0.00

$0.04

-

-

$0.00

-

-

-

-

$0.00

-

$0.00

-

$0.00

-

-

-

$0.00

-

-

$0.00
Piece Cost 

(Total)

$0.97

-

-

-

$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

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

$0.00

$0.00

$1.25

$0.00

$0.00

$0.00

$0.00

$1.19

$0.00

$0.00

-

$0.00

Piece Cost 

(Total)

-

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

$0.00

Piece Cost 

(Total)

$0.75

-

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

$0.00

$0.00

Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

-

-

-

-

-

-

$0.00

-

$0.00

-

$0.00

$0.15
Piece Cost 

(Total)

-

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$0.00

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

$0.00

-

$0.00

$7.02

-

$0.00
Piece Cost 

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.08

$0.00

$0.02

-

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$0.00

-

$0.00

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Cost 

(Total)

-

-

-

-

-

-

-

-

-

-

$0.00

$0.45

$0.20

$0.00

$0.03

$0.00

$0.00

-

-

$0.00

$0.00

-

$0.00
Piece Cost 

(Total)

$0.08

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Cost 

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Cost 

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

$0.00

-

-

-

-

-

-

$0.00
Piece Cost 

(Total)

-

-

-

-

$0.00

-

-

$0.00

-

$0.00

$1.00

-

$0.27

$0.16

$0.00

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$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

$1.51

$0.00

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$0.00

$0.00

$0.08

$0.00

$0.00

$0.00

-

$0.02

$0.00

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Cost 

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

$0.00

$0.05

-

$0.00

-

-

$0.00

-

$0.00

-
Piece Cost 

(Total)

$0.00

-

$0.00

-

$0.00

$0.13

-

-

-

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.00

Piece Cost 

(Total)

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

$0.00

Piece Cost 

(Total)

-

$0.00

-

$0.00

$0.17

-

-

-

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$0.09

$0.00

-

-

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.03

-

-

-

-

-

-

-

-

-

-

-

-
Piece Cost 

(Total)

-

-

-

$0.00

-

-

$0.00

-

$0.00

-

$0.00

-

$0.00

$0.64

-

-

-

$0.00

$0.00

$0.00

$0.00

-

$0.00

Piece Cost 

(Total)

$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

-

-

-

-

-
Piece Cost 

(Total)

-

-

-

-

-

$0.00

-

-

$0.00

-

$0.00

-

$0.00

-

$0.39

-

-

-

Piece Cost 

(Total)

$0.00

-

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$0.00

-

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Cost 

(Total)

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.05

-

$0.00

$0.00

Piece Cost 

(Total)

$0.02

$0.00

$0.00

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Cost 

(Total)

-

$0.00

$0.21

-

-

-

$0.00

$0.04

$0.00

$0.00

$0.00

-

$0.00

-

-

$0.00

-

$0.00

$0.01

-

-
Piece Cost 

(Total)

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.01

$0.00

$0.00

-

$0.00

$0.06

$0.00

$0.00

$0.00

$0.22

$0.00

$0.00
Piece Cost 

(Total)

$26.86
Assembly Report

G Swash Plate, AC Pump

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$20.81 Tool G Swash Plate, Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Pump

$32.17 P.-P. Part G Swash Plate, G Swash Plate, AC G Swash Plate, 3.0000 sec 3.0000 sec - $0.02 1

AC Pump Pump-Machined AC 

Pump-Machined

Media:

$32.17 Tool G Swash Plate, CNC Turning 4 Axis SL-10, Odd 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Form

Pump-Machined

$43.52 P.-P. Part G Swash Plate, G Swash Plate, AC Pump-Trimed G Swash Plate, 0.0000 sec 0.0000 sec - $0.00 1

AC AC Pump-Trimed

Pump-Machined

Media:

$43.52 Tool G Swash Plate, Trim Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Pump-Trimed

$56.87 P.-P. Part G Swash Plate, G Swash Plate, AC Pump-pretrim G Swash Plate, 5.0000 sec 5.0000 sec - $0.06 1

AC Pump-Trimed AC Pump-pretrim

Media:

Design Profit ®

Page 1 of 5

Copyright 2005© Munro & Associates, Inc.
G Swash Plate, AC Pump

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

- - - "Mold Making - Sand Casting, - - - - - -

Small-Medium Size and

$56.87 Tool G Swash Plate, Sand-core removal 25EZ155-175 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Pump-pretrim

##### P.-P. Part G Swash Plate, G Swash Plate, AC Pump-shake G Swash Plate, 5.0000 sec 5.0000 sec - $0.08 1

AC Pump-pretrim out AC Pump-shake 

out

Media:

- - - "Mold Making - Sand Casting, - - - - - -

Small-Medium Size and

##### Tool G Swash Plate, Mold Making DISA 240 w/100 m 0.0000 sec 0.0000 sec $0.00 $0.00 1

AC Pump-shake Cooling Line

out

Media:

- - - 8 cavity Mold 2x4 - - - - - -

##### Part G Swash Plate, G Swash Plate, AC Pump-Cast G Swash Plate, 0.0000 sec 0.0000 sec $0.20 $0.00 1

AC Pump-shake Material AC Pump-Cast 

out Material

Media:

- - - 0.47 lbs for cast part $0.42 per lb - - - - - -

Design Profit ®

Page 2 of 5

Copyright 2005© Munro & Associates, Inc.
G Swash Plate, AC Pump

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

##### Part G Swash Plate, G Swash Plate, AC Pump-Energy G Swash Plate, 0.0000 sec 0.0000 sec $0.03 $0.00 1

AC Pump-shake AC Pump-Energy

out

Media:

##### Part G Swash Plate, G Swash Plate, AC Pump-Lost G Swash Plate, 0.0000 sec 0.0160 sec $0.03 $0.00 1

AC Pump-shake Sand AC Pump-Lost 

out Sand

Media:

$56.87 Operation G Swash Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 1

AC Pump-pretrim

$56.87 Material Mod. Material Mod. G Swash Plate, G Swash Plate, Remove Mold Sand No Cores Remove Mold Sand No Cores 5.0000 sec 5.0000 sec 5.0000 sec 5.0000 sec $0.00 $0.08 1

AC Pump-pretrim

$56.87 Operation G Swash Plate, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

AC Pump-pretrim

$43.52 Operation G Swash Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

AC Pump-Trimed

$43.52 Operation G Swash Plate, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

AC Pump-Trimed

$43.52 Material Mod. G Swash Plate, Trim Flash/Gates 3.0000 sec 3.0000 sec $0.00 $0.04 1

AC Pump-Trimed

$43.52 Operation G Swash Plate, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

AC Pump-Trimed

$43.52 Operation G Swash Plate, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

AC Pump-Trimed

$32.17 Operation G Swash Plate, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

AC 

Pump-Machined

Design Profit ®

Page 3 of 5

Copyright 2005© Munro & Associates, Inc.
G Swash Plate, AC Pump

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$32.17 Material Mod. G Swash Plate, Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

AC 

Pump-Machined

$32.17 Operation G Swash Plate, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

AC 

Pump-Machined

- - - Multi tool stepped face - - - - - -

$32.17 Material Mod. G Swash Plate, Spot Face 2.0000 sec 2.0000 sec $0.00 $0.02 1

AC 

Pump-Machined

$32.17 Operation G Swash Plate, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

AC 

Pump-Machined

$32.17 Material Mod. G Swash Plate, Turn Face Contoured 5.0000 sec 5.0000 sec $0.00 $0.04 1

AC 

Pump-Machined

$32.17 Operation G Swash Plate, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

AC 

Pump-Machined

$32.17 Material Mod. G Swash Plate, Gound end face swash plate 5.0000 sec 5.0000 sec $0.00 $0.04 1

AC 

Pump-Machined

$32.17 Operation G Swash Plate, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

AC 

Pump-Machined

$32.17 Operation G Swash Plate, Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 1

AC 

Pump-Machined

$32.17 Operation G Swash Plate, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

AC 

Pump-Machined

$32.17 Material Mod. G Swash Plate, Spot Face 2.0000 sec 2.0000 sec $0.00 $0.02 1

AC 

Pump-Machined

$32.17 Operation G Swash Plate, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

AC 

Pump-Machined

$32.17 Material Mod. G Swash Plate, Turn Face Contoured 5.0000 sec 5.0000 sec $0.00 $0.04 1

AC 

Pump-Machined

$32.17 Operation G Swash Plate, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 1

AC 

Pump-Machined

Design Profit ®
Page 

4 of5

Copyright 2005© Munro & Associates, Inc.
G Swash Plate, AC Pump

Labor Type Parent Name Symbol Name Number Munro Actual Time Piece Cost Total Labor Qty

Rate Score Cost (Total)

$32.17 Material Mod. G Swash Plate, Gound end face swash plate 5.0000 sec 5.0000 sec $0.00 $0.04 1

AC 

Pump-Machined

$32.17 Operation G Swash Plate, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

AC 

Pump-Machined

- - - Broaching of inner spline - - - - - -

$32.17 Operation G Swash Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

AC 

Pump-Machined

$32.17 Operation G Swash Plate, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

AC 

Pump-Machined

$32.17 Material Mod. G Swash Plate, Broach Steel 1 ft lng tool 1.5000 sec 1.5000 sec $0.00 $0.01 1

AC 

Pump-Machined

$32.17 Operation G Swash Plate, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

AC 

Pump-Machined

$32.17 Operation G Swash Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

AC 

Pump-Machined

$20.81 Operation G Swash Plate, Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 1

AC Pump

$20.81 Operation G Swash Plate, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.03 1

AC Pump

$20.81 Operation G Swash Plate, Remove Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

AC Pump

Report Totals Count: 51

45

Design Profit ®

Page 5 of 5

Copyright 2005© Munro & Associates, Inc.
Piece Cost 

(Total)

$0.00

-

$0.00

-

$0.00

-
Piece Cost 

(Total)

-

$0.00

-

-

$0.00

-

$0.20

-
Piece Cost 

(Total)

$0.03

$0.03

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00
Piece Cost 

(Total)

$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

Piece Cost 

(Total)

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.26
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#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, HEV, Electrically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

File: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#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, HEV, Electrically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

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)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

File: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#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, HEV, Electrically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

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)

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

3 0 $0.00 $0.00 $0.00 $0.00 $0.00

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

5 0 $0.00 $0.00 $0.00 $0.00 $0.00

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

7 0 $0.00 $0.00 $0.00 $0.00 $0.00

8 0 $0.00 $0.00 $0.00 $0.00 $0.00

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

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

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

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

Mark-up Calculations.

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

Supplier for Subassembly. 9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Material

$0.00

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

Mark-up $0.00

T1 or OEM Total Manufacturing Cost: $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- #N/A #N/A #N/A #N/A #N/A

Supplier for Subassembly.

3

1

Notes: 

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

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- #N/A #N/A #N/A #N/A #N/A

Base Cost Impact to Vehicle: $0.00 $0.00 $0.00 $0.00 #N/A #N/A #N/A #N/A #N/A #N/A $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: #N/A

a) Items 1,2, & 3 must a

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

File: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#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2010 Ford Fusion, HEV, Electrically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

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)

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

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! 85% 0 #DIV/0! - - - - 1.0 1.0

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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! #DIV/0! 85% 0 #DIV/0! #DIV/0! - - - - 1.0 1.0

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

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

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

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

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

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

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

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

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

File: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.

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

$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! -

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! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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.

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

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
Page:1 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

03 Refridgeration/Air Conditioning Subsystem

01 G AC Pump Assembly # # # - B0602 - # 1

G Snap-ring, AC Magnet # # # - B0602 - 02 1 PIA

G Snap-ring, AC Hub # # # - B0602 - 03 1 PIA

G Shim, Clutch Hub # # # - B0602 - 04 2 PIA

G Bolt, AC Clutch Hub Cover # # # - B0602 - 05 3 PIA

G Bolt, Bracket, AC Electrical # # # - B0602 - 06 1 PIA

G Bolt, Short, AC Asm to Hoses # # # - B0602 - # 1 PIA

G Bolt, Long, AC Asm. to Bracket # # # - B0602 - # 1 PIA

A G Center Pump Assembly # # # - B0602 - 07 1

G Spacer, Shaft, Large # # # - B0602 - 08 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 09 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 10 1 PIA

G Bearing, Swash Plate to Piston # # # - B0602 - 11 10 PIA

G Spacer, Shaft, Large # # # - B0602 - 12 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 13 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 14 1 PIA

G Gasket, Pump Housing # # # - B0602 - 15 1 PIA

G Bolt, Front to Rear Housing # # # - B0602 - 16 3 PIA

G Bolt, Front Cover to Rear # # # - B0602 - # 5

B G Rear Pump Housing Assemby # # # - B0602 - 17 1

 G Label, Front Pump Housing # # # - B0602 - 18 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 19 1 PIA

G Dowel, Small, Rear Housing # # # - B0602 - 20 3 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 21 1 PIA

C G Shaft and Swash Plate Asm. # # # - B0602 - 22 1 C1 & C2

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

C2 G Swash Plate, AC Pump # # # - B0602 - 24 1 PIA

D G Piston Asm. AC Compressor # # # - B0602 - 25 5

G Piston, AC Compressor # # # - B0602 - 26 1 PIA

G Seal, Piston, AC Compressor # # # - B0602 - 27 1 PIA

E G Front Pump Housing, Asm # # # - B0602 - 28 1

 G Label, Front Pump Housing # # # - B0602 29 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 30 1 PIA

G Dowel, Large Front Housing # # # - B0602 - 31 2 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 32 1 PIA

E1 G Steel Valve, AC Pump # # # - B0602 - 33 1

E2 G Valve Plate, Front Cover Assembly # # # - B0602 - 34 1

G Valve Plate, Base # # # - B0602 35 1 PIA

G Valve Plate, Valve # # # - B0602 36 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 37 1 PIA

G Valve Plate, Pin # # # - B0602 - 38 4 PIA

E3 G Gasket, Front Cover # # # - B0602 - 39 1

F G Front Cover Asm. # # # - B0602 - 40 1

G Seal, Front Cover # # # - B0602 - 41 1 PIA

G Snap-ring, Seal Front Cover # # # - B0602 - 42 1 PIA

G Dust Seal, Cloth, Front Cover # # # - B0602 - 43 1 PIA

F1 G Steel Valve, AC Pump # # # - B0602 - 44 1

F2 G Valve Plate, Rear Cover, Assembly # # # - B0602 - 45 1

G Valve Plate, Base # # # - B0602 46 1 PIA

G Valve Plate, Valve # # # - B0602 47 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 48 1 PIA

G Valve Plate, Pin # # # - B0602 - 49 4 PIA

F3 G Gasket, Rear Cover # # # - B0602 - 50 1

G G Rear Cover Asm. # # # - B0602 - 51 1

G O-ring, Plug, Rear Cover # # # - B0602 - 52 1 PIA

G Plug Asm. , Rear Cover # # # - B0602 - 53 1 PIA

H G Magnet Asm., AC Clutch # # # - B0602 - 54 1

G Snap-ring, AC Magnet # # # - B0602 55 1 PIA

G Magnet Asm, Pigtail Connector # # # - B0602 56 1 PIA

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:2 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

G Magnet Asm, Connector # # # - B0602 57 1 PIA

G Magnet Asm, Liner # # # - B0602 58 1 PIA

I G Clutch Hub Asm. # # # - B0602 - 59 1 I1,I2,I3,I4

G Clutch Hub, Washer, M5 # # # - B0602 60 3 PIA

G Clutch Hub, Rivet Pin, M5 # # # - B0602 61 3 PIA

G Clutch Hub, Rivet Pin, M6 # # # - B0602 62 3 PIA

I1 G Clutch Hub, Splined Hub, Painted # # # - B0602 64 1

I2 G Clutch Hub, Face # # # - B0602 65 1

I3 G Clutch Hub, Isolator,Painted, Asm # # # - B0602 66 1

I4 G Clutch Hub, Cover, Molded # # # - B0602 - 67 1

J G Bracket, Stamped, AC # # # - B0602 - 68 1

K G Clutch Pully Asm # # # - B0602 - 69 1

G Clutch Pully, Friction Material # # # - B0602 - # 1 PIA

G Clutch Pulley, Bearing # # # - B0602 - # 1 PIA

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:3 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:4 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:5 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

NOTES:

1.

Complete Subsystem Quote 

(Yes/No)

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

the competing technology

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:6 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

03 Refridgeration/Air Conditioning Subsystem

01 G AC Pump Assembly # # # - B0602 - # 1

G Snap-ring, AC Magnet # # # - B0602 - 02 1 PIA

G Snap-ring, AC Hub # # # - B0602 - 03 1 PIA

G Shim, Clutch Hub # # # - B0602 - 04 2 PIA

G Bolt, AC Clutch Hub Cover # # # - B0602 - 05 3 PIA

G Bolt, Bracket, AC Electrical # # # - B0602 - 06 1 PIA

G Bolt, Short, AC Asm to Hoses # # # - B0602 - # 1 PIA

G Bolt, Long, AC Asm. to Bracket # # # - B0602 - # 1 PIA

A G Center Pump Assembly # # # - B0602 - 07 1

G Spacer, Shaft, Large # # # - B0602 - 08 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 09 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 10 1 PIA

G Bearing, Swash Plate to Piston # # # - B0602 - 11 10 PIA

G Spacer, Shaft, Large # # # - B0602 - 12 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 13 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 14 1 PIA

G Gasket, Pump Housing # # # - B0602 - 15 1 PIA

G Bolt, Front to Rear Housing # # # - B0602 - 16 3 PIA

G Bolt, Front Cover to Rear # # # - B0602 - # 5

B G Rear Pump Housing Assemby # # # - B0602 - 17 1

 G Label, Front Pump Housing # # # - B0602 - 18 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 19 1 PIA

G Dowel, Small, Rear Housing # # # - B0602 - 20 3 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 21 1 PIA

C G Shaft and Swash Plate Asm. # # # - B0602 - 22 1 C1 & C2

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Material

$ -

$24.10

$0.50

$4.19

$1.73

$1.16

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

C2 G Swash Plate, AC Pump # # # - B0602 - 24 1 PIA

D G Piston Asm. AC Compressor # # # - B0602 - 25 5

G Piston, AC Compressor # # # - B0602 - 26 1 PIA

G Seal, Piston, AC Compressor # # # - B0602 - 27 1 PIA

E G Front Pump Housing, Asm # # # - B0602 - 28 1

 G Label, Front Pump Housing # # # - B0602 29 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 30 1 PIA

G Dowel, Large Front Housing # # # - B0602 - 31 2 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 32 1 PIA

E1 G Steel Valve, AC Pump # # # - B0602 - 33 1

E2 G Valve Plate, Front Cover Assembly # # # - B0602 - 34 1

G Valve Plate, Base # # # - B0602 35 1 PIA

G Valve Plate, Valve # # # - B0602 36 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 37 1 PIA

G Valve Plate, Pin # # # - B0602 - 38 4 PIA

E3 G Gasket, Front Cover # # # - B0602 - 39 1

F G Front Cover Asm. # # # - B0602 - 40 1

G Seal, Front Cover # # # - B0602 - 41 1 PIA

G Snap-ring, Seal Front Cover # # # - B0602 - 42 1 PIA

G Dust Seal, Cloth, Front Cover # # # - B0602 - 43 1 PIA

F1 G Steel Valve, AC Pump # # # - B0602 - 44 1

F2 G Valve Plate, Rear Cover, Assembly # # # - B0602 - 45 1

G Valve Plate, Base # # # - B0602 46 1 PIA

G Valve Plate, Valve # # # - B0602 47 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 48 1 PIA

G Valve Plate, Pin # # # - B0602 - 49 4 PIA

F3 G Gasket, Rear Cover # # # - B0602 - 50 1

G G Rear Cover Asm. # # # - B0602 - 51 1

G O-ring, Plug, Rear Cover # # # - B0602 - 52 1 PIA

G Plug Asm. , Rear Cover # # # - B0602 - 53 1 PIA

H G Magnet Asm., AC Clutch # # # - B0602 - 54 1

G Snap-ring, AC Magnet # # # - B0602 55 1 PIA

G Magnet Asm, Pigtail Connector # # # - B0602 56 1 PIA

$1.46

$2.71

$0.18

$1.60

$0.20

$ 1.64

$4.14

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:7 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

G Magnet Asm, Connector # # # - B0602 57 1 PIA

G Magnet Asm, Liner # # # - B0602 58 1 PIA

I G Clutch Hub Asm. # # # - B0602 - 59 1 I1,I2,I3,I4

G Clutch Hub, Washer, M5 # # # - B0602 60 3 PIA

G Clutch Hub, Rivet Pin, M5 # # # - B0602 61 3 PIA

G Clutch Hub, Rivet Pin, M6 # # # - B0602 62 3 PIA

I1 G Clutch Hub, Splined Hub, Painted # # # - B0602 64 1

I2 G Clutch Hub, Face # # # - B0602 65 1

I3 G Clutch Hub, Isolator,Painted, Asm # # # - B0602 66 1

I4 G Clutch Hub, Cover, Molded # # # - B0602 - 67 1

J G Bracket, Stamped, AC # # # - B0602 - 68 1

K G Clutch Pully Asm # # # - B0602 - 69 1

G Clutch Pully, Friction Material # # # - B0602 - # 1 PIA

G Clutch Pulley, Bearing # # # - B0602 - # 1 PIA

Material

$1.11

$0.01

$3.48

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:8 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Material

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:9 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Material

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:10 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

NOTES:

1.

Complete Subsystem Quote 

(Yes/No)

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

the competing technology

Material

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:11 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

03 Refridgeration/Air Conditioning Subsystem

01 G AC Pump Assembly # # # - B0602 - # 1

G Snap-ring, AC Magnet # # # - B0602 - 02 1 PIA

G Snap-ring, AC Hub # # # - B0602 - 03 1 PIA

G Shim, Clutch Hub # # # - B0602 - 04 2 PIA

G Bolt, AC Clutch Hub Cover # # # - B0602 - 05 3 PIA

G Bolt, Bracket, AC Electrical # # # - B0602 - 06 1 PIA

G Bolt, Short, AC Asm to Hoses # # # - B0602 - # 1 PIA

G Bolt, Long, AC Asm. to Bracket # # # - B0602 - # 1 PIA

A G Center Pump Assembly # # # - B0602 - 07 1

G Spacer, Shaft, Large # # # - B0602 - 08 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 09 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 10 1 PIA

G Bearing, Swash Plate to Piston # # # - B0602 - 11 10 PIA

G Spacer, Shaft, Large # # # - B0602 - 12 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 13 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 14 1 PIA

G Gasket, Pump Housing # # # - B0602 - 15 1 PIA

G Bolt, Front to Rear Housing # # # - B0602 - 16 3 PIA

G Bolt, Front Cover to Rear # # # - B0602 - # 5

B G Rear Pump Housing Assemby # # # - B0602 - 17 1

 G Label, Front Pump Housing # # # - B0602 - 18 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 19 1 PIA

G Dowel, Small, Rear Housing # # # - B0602 - 20 3 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 21 1 PIA

C G Shaft and Swash Plate Asm. # # # - B0602 - 22 1 C1 & C2

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Labor

$ -

$19.18

$0.29

$0.39

$1.95

$1.18

Manufacturing 

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

C2 G Swash Plate, AC Pump # # # - B0602 - 24 1 PIA

D G Piston Asm. AC Compressor # # # - B0602 - 25 5

G Piston, AC Compressor # # # - B0602 - 26 1 PIA

G Seal, Piston, AC Compressor # # # - B0602 - 27 1 PIA

E G Front Pump Housing, Asm # # # - B0602 - 28 1

 G Label, Front Pump Housing # # # - B0602 29 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 30 1 PIA

G Dowel, Large Front Housing # # # - B0602 - 31 2 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 32 1 PIA

E1 G Steel Valve, AC Pump # # # - B0602 - 33 1

E2 G Valve Plate, Front Cover Assembly # # # - B0602 - 34 1

G Valve Plate, Base # # # - B0602 35 1 PIA

G Valve Plate, Valve # # # - B0602 36 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 37 1 PIA

G Valve Plate, Pin # # # - B0602 - 38 4 PIA

E3 G Gasket, Front Cover # # # - B0602 - 39 1

F G Front Cover Asm. # # # - B0602 - 40 1

G Seal, Front Cover # # # - B0602 - 41 1 PIA

G Snap-ring, Seal Front Cover # # # - B0602 - 42 1 PIA

G Dust Seal, Cloth, Front Cover # # # - B0602 - 43 1 PIA

F1 G Steel Valve, AC Pump # # # - B0602 - 44 1

F2 G Valve Plate, Rear Cover, Assembly # # # - B0602 - 45 1

G Valve Plate, Base # # # - B0602 46 1 PIA

G Valve Plate, Valve # # # - B0602 47 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 48 1 PIA

G Valve Plate, Pin # # # - B0602 - 49 4 PIA

F3 G Gasket, Rear Cover # # # - B0602 - 50 1

G G Rear Cover Asm. # # # - B0602 - 51 1

G O-ring, Plug, Rear Cover # # # - B0602 - 52 1 PIA

G Plug Asm. , Rear Cover # # # - B0602 - 53 1 PIA

H G Magnet Asm., AC Clutch # # # - B0602 - 54 1

G Snap-ring, AC Magnet # # # - B0602 55 1 PIA

G Magnet Asm, Pigtail Connector # # # - B0602 56 1 PIA

$3.64

$2.07

$0.68

$1.73

$0.49

$ 1.26

$2.23

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:12 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

G Magnet Asm, Connector # # # - B0602 57 1 PIA

G Magnet Asm, Liner # # # - B0602 58 1 PIA

I G Clutch Hub Asm. # # # - B0602 - 59 1 I1,I2,I3,I4

G Clutch Hub, Washer, M5 # # # - B0602 60 3 PIA

G Clutch Hub, Rivet Pin, M5 # # # - B0602 61 3 PIA

G Clutch Hub, Rivet Pin, M6 # # # - B0602 62 3 PIA

I1 G Clutch Hub, Splined Hub, Painted # # # - B0602 64 1

I2 G Clutch Hub, Face # # # - B0602 65 1

I3 G Clutch Hub, Isolator,Painted, Asm # # # - B0602 66 1

I4 G Clutch Hub, Cover, Molded # # # - B0602 - 67 1

J G Bracket, Stamped, AC # # # - B0602 - 68 1

K G Clutch Pully Asm # # # - B0602 - 69 1

G Clutch Pully, Friction Material # # # - B0602 - # 1 PIA

G Clutch Pulley, Bearing # # # - B0602 - # 1 PIA

Labor

Manufacturing 

$1.77

$0.01

$1.49

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:13 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Labor

Manufacturing 

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:14 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Labor

Manufacturing 

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:15 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

NOTES:

1.

Complete Subsystem Quote 

(Yes/No)

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

the competing technology

Labor

Manufacturing 

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:16 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

03 Refridgeration/Air Conditioning Subsystem

01 G AC Pump Assembly # # # - B0602 - # 1

G Snap-ring, AC Magnet # # # - B0602 - 02 1 PIA

G Snap-ring, AC Hub # # # - B0602 - 03 1 PIA

G Shim, Clutch Hub # # # - B0602 - 04 2 PIA

G Bolt, AC Clutch Hub Cover # # # - B0602 - 05 3 PIA

G Bolt, Bracket, AC Electrical # # # - B0602 - 06 1 PIA

G Bolt, Short, AC Asm to Hoses # # # - B0602 - # 1 PIA

G Bolt, Long, AC Asm. to Bracket # # # - B0602 - # 1 PIA

A G Center Pump Assembly # # # - B0602 - 07 1

G Spacer, Shaft, Large # # # - B0602 - 08 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 09 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 10 1 PIA

G Bearing, Swash Plate to Piston # # # - B0602 - 11 10 PIA

G Spacer, Shaft, Large # # # - B0602 - 12 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 13 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 14 1 PIA

G Gasket, Pump Housing # # # - B0602 - 15 1 PIA

G Bolt, Front to Rear Housing # # # - B0602 - 16 3 PIA

G Bolt, Front Cover to Rear # # # - B0602 - # 5

B G Rear Pump Housing Assemby # # # - B0602 - 17 1

 G Label, Front Pump Housing # # # - B0602 - 18 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 19 1 PIA

G Dowel, Small, Rear Housing # # # - B0602 - 20 3 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 21 1 PIA

C G Shaft and Swash Plate Asm. # # # - B0602 - 22 1 C1 & C2

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Burden

$ -

$25.92

$1.05

$1.50

$2.29

$1.49

Manufacturing 

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

C2 G Swash Plate, AC Pump # # # - B0602 - 24 1 PIA

D G Piston Asm. AC Compressor # # # - B0602 - 25 5

G Piston, AC Compressor # # # - B0602 - 26 1 PIA

G Seal, Piston, AC Compressor # # # - B0602 - 27 1 PIA

E G Front Pump Housing, Asm # # # - B0602 - 28 1

 G Label, Front Pump Housing # # # - B0602 29 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 30 1 PIA

G Dowel, Large Front Housing # # # - B0602 - 31 2 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 32 1 PIA

E1 G Steel Valve, AC Pump # # # - B0602 - 33 1

E2 G Valve Plate, Front Cover Assembly # # # - B0602 - 34 1

G Valve Plate, Base # # # - B0602 35 1 PIA

G Valve Plate, Valve # # # - B0602 36 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 37 1 PIA

G Valve Plate, Pin # # # - B0602 - 38 4 PIA

E3 G Gasket, Front Cover # # # - B0602 - 39 1

F G Front Cover Asm. # # # - B0602 - 40 1

G Seal, Front Cover # # # - B0602 - 41 1 PIA

G Snap-ring, Seal Front Cover # # # - B0602 - 42 1 PIA

G Dust Seal, Cloth, Front Cover # # # - B0602 - 43 1 PIA

F1 G Steel Valve, AC Pump # # # - B0602 - 44 1

F2 G Valve Plate, Rear Cover, Assembly # # # - B0602 - 45 1

G Valve Plate, Base # # # - B0602 46 1 PIA

G Valve Plate, Valve # # # - B0602 47 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 48 1 PIA

G Valve Plate, Pin # # # - B0602 - 49 4 PIA

F3 G Gasket, Rear Cover # # # - B0602 - 50 1

G G Rear Cover Asm. # # # - B0602 - 51 1

G O-ring, Plug, Rear Cover # # # - B0602 - 52 1 PIA

G Plug Asm. , Rear Cover # # # - B0602 - 53 1 PIA

H G Magnet Asm., AC Clutch # # # - B0602 - 54 1

G Snap-ring, AC Magnet # # # - B0602 55 1 PIA

G Magnet Asm, Pigtail Connector # # # - B0602 56 1 PIA

$5.46

$3.53

$0.92

$2.18

$0.74

$ 1.53

$1.71

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:17 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

G Magnet Asm, Connector # # # - B0602 57 1 PIA

G Magnet Asm, Liner # # # - B0602 58 1 PIA

I G Clutch Hub Asm. # # # - B0602 - 59 1 I1,I2,I3,I4

G Clutch Hub, Washer, M5 # # # - B0602 60 3 PIA

G Clutch Hub, Rivet Pin, M5 # # # - B0602 61 3 PIA

G Clutch Hub, Rivet Pin, M6 # # # - B0602 62 3 PIA

I1 G Clutch Hub, Splined Hub, Painted # # # - B0602 64 1

I2 G Clutch Hub, Face # # # - B0602 65 1

I3 G Clutch Hub, Isolator,Painted, Asm # # # - B0602 66 1

I4 G Clutch Hub, Cover, Molded # # # - B0602 - 67 1

J G Bracket, Stamped, AC # # # - B0602 - 68 1

K G Clutch Pully Asm # # # - B0602 - 69 1

G Clutch Pully, Friction Material # # # - B0602 - # 1 PIA

G Clutch Pulley, Bearing # # # - B0602 - # 1 PIA

Burden

Manufacturing 

$2.05

$0.02

$1.43

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:18 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Burden

Manufacturing 

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:19 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Burden

Manufacturing 

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:20 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

NOTES:

1.

Complete Subsystem Quote 

(Yes/No)

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

the competing technology

Burden

Manufacturing 

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:21 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

03 Refridgeration/Air Conditioning Subsystem

01 G AC Pump Assembly # # # - B0602 - # 1

G Snap-ring, AC Magnet # # # - B0602 - 02 1 PIA

G Snap-ring, AC Hub # # # - B0602 - 03 1 PIA

G Shim, Clutch Hub # # # - B0602 - 04 2 PIA

G Bolt, AC Clutch Hub Cover # # # - B0602 - 05 3 PIA

G Bolt, Bracket, AC Electrical # # # - B0602 - 06 1 PIA

G Bolt, Short, AC Asm to Hoses # # # - B0602 - # 1 PIA

G Bolt, Long, AC Asm. to Bracket # # # - B0602 - # 1 PIA

A G Center Pump Assembly # # # - B0602 - 07 1

G Spacer, Shaft, Large # # # - B0602 - 08 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 09 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 10 1 PIA

G Bearing, Swash Plate to Piston # # # - B0602 - 11 10 PIA

G Spacer, Shaft, Large # # # - B0602 - 12 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 13 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 14 1 PIA

G Gasket, Pump Housing # # # - B0602 - 15 1 PIA

G Bolt, Front to Rear Housing # # # - B0602 - 16 3 PIA

G Bolt, Front Cover to Rear # # # - B0602 - # 5

B G Rear Pump Housing Assemby # # # - B0602 - 17 1

 G Label, Front Pump Housing # # # - B0602 - 18 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 19 1 PIA

G Dowel, Small, Rear Housing # # # - B0602 - 20 3 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 21 1 PIA

C G Shaft and Swash Plate Asm. # # # - B0602 - 22 1 C1 & C2

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

$ -

$ 69.20

$1.84

$6.08

$5.97

$3.83

Total 

Manufact

uring 

Cost 

(Compon

ent/ 

Assembl

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

C2 G Swash Plate, AC Pump # # # - B0602 - 24 1 PIA

D G Piston Asm. AC Compressor # # # - B0602 - 25 5

G Piston, AC Compressor # # # - B0602 - 26 1 PIA

G Seal, Piston, AC Compressor # # # - B0602 - 27 1 PIA

E G Front Pump Housing, Asm # # # - B0602 - 28 1

 G Label, Front Pump Housing # # # - B0602 29 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 30 1 PIA

G Dowel, Large Front Housing # # # - B0602 - 31 2 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 32 1 PIA

E1 G Steel Valve, AC Pump # # # - B0602 - 33 1

E2 G Valve Plate, Front Cover Assembly # # # - B0602 - 34 1

G Valve Plate, Base # # # - B0602 35 1 PIA

G Valve Plate, Valve # # # - B0602 36 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 37 1 PIA

G Valve Plate, Pin # # # - B0602 - 38 4 PIA

E3 G Gasket, Front Cover # # # - B0602 - 39 1

F G Front Cover Asm. # # # - B0602 - 40 1

G Seal, Front Cover # # # - B0602 - 41 1 PIA

G Snap-ring, Seal Front Cover # # # - B0602 - 42 1 PIA

G Dust Seal, Cloth, Front Cover # # # - B0602 - 43 1 PIA

F1 G Steel Valve, AC Pump # # # - B0602 - 44 1

F2 G Valve Plate, Rear Cover, Assembly # # # - B0602 - 45 1

G Valve Plate, Base # # # - B0602 46 1 PIA

G Valve Plate, Valve # # # - B0602 47 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 48 1 PIA

G Valve Plate, Pin # # # - B0602 - 49 4 PIA

F3 G Gasket, Rear Cover # # # - B0602 - 50 1

G G Rear Cover Asm. # # # - B0602 - 51 1

G O-ring, Plug, Rear Cover # # # - B0602 - 52 1 PIA

G Plug Asm. , Rear Cover # # # - B0602 - 53 1 PIA

H G Magnet Asm., AC Clutch # # # - B0602 - 54 1

G Snap-ring, AC Magnet # # # - B0602 55 1 PIA

G Magnet Asm, Pigtail Connector # # # - B0602 56 1 PIA

$10.56

$8.30

$1.78

$5.52

$1.42

$ 4.44

$8.07

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:22 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

G Magnet Asm, Connector # # # - B0602 57 1 PIA

G Magnet Asm, Liner # # # - B0602 58 1 PIA

I G Clutch Hub Asm. # # # - B0602 - 59 1 I1,I2,I3,I4

G Clutch Hub, Washer, M5 # # # - B0602 60 3 PIA

G Clutch Hub, Rivet Pin, M5 # # # - B0602 61 3 PIA

G Clutch Hub, Rivet Pin, M6 # # # - B0602 62 3 PIA

I1 G Clutch Hub, Splined Hub, Painted # # # - B0602 64 1

I2 G Clutch Hub, Face # # # - B0602 65 1

I3 G Clutch Hub, Isolator,Painted, Asm # # # - B0602 66 1

I4 G Clutch Hub, Cover, Molded # # # - B0602 - 67 1

J G Bracket, Stamped, AC # # # - B0602 - 68 1

K G Clutch Pully Asm # # # - B0602 - 69 1

G Clutch Pully, Friction Material # # # - B0602 - # 1 PIA

G Clutch Pulley, Bearing # # # - B0602 - # 1 PIA

Total 

Manufact

uring 

Cost 

(Compon

ent/ 

Assembl

$4.94

$0.04

$6.40

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:23 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Total 

Manufact

uring 

Cost 

(Compon

ent/ 

Assembl

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:24 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Total 

Manufact

uring 

Cost 

(Compon

ent/ 

Assembl

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:25 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

NOTES:

1.

Complete Subsystem Quote 

(Yes/No)

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

the competing technology

Total 

Manufact

uring 

Cost 

(Compon

ent/ 

Assembl

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:26 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

03 Refridgeration/Air Conditioning Subsystem

01 G AC Pump Assembly # # # - B0602 - # 1

G Snap-ring, AC Magnet # # # - B0602 - 02 1 PIA

G Snap-ring, AC Hub # # # - B0602 - 03 1 PIA

G Shim, Clutch Hub # # # - B0602 - 04 2 PIA

G Bolt, AC Clutch Hub Cover # # # - B0602 - 05 3 PIA

G Bolt, Bracket, AC Electrical # # # - B0602 - 06 1 PIA

G Bolt, Short, AC Asm to Hoses # # # - B0602 - # 1 PIA

G Bolt, Long, AC Asm. to Bracket # # # - B0602 - # 1 PIA

A G Center Pump Assembly # # # - B0602 - 07 1

G Spacer, Shaft, Large # # # - B0602 - 08 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 09 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 10 1 PIA

G Bearing, Swash Plate to Piston # # # - B0602 - 11 10 PIA

G Spacer, Shaft, Large # # # - B0602 - 12 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 13 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 14 1 PIA

G Gasket, Pump Housing # # # - B0602 - 15 1 PIA

G Bolt, Front to Rear Housing # # # - B0602 - 16 3 PIA

G Bolt, Front Cover to Rear # # # - B0602 - # 5

B G Rear Pump Housing Assemby # # # - B0602 - 17 1

 G Label, Front Pump Housing # # # - B0602 - 18 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 19 1 PIA

G Dowel, Small, Rear Housing # # # - B0602 - 20 3 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 21 1 PIA

C G Shaft and Swash Plate Asm. # # # - B0602 - 22 1 C1 & C2

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

End Item 

Scrap

$ -

$0.58

$0.01

$0.04

$0.03

$0.08

BASE TECHNOLOG

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

C2 G Swash Plate, AC Pump # # # - B0602 - 24 1 PIA

D G Piston Asm. AC Compressor # # # - B0602 - 25 5

G Piston, AC Compressor # # # - B0602 - 26 1 PIA

G Seal, Piston, AC Compressor # # # - B0602 - 27 1 PIA

E G Front Pump Housing, Asm # # # - B0602 - 28 1

 G Label, Front Pump Housing # # # - B0602 29 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 30 1 PIA

G Dowel, Large Front Housing # # # - B0602 - 31 2 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 32 1 PIA

E1 G Steel Valve, AC Pump # # # - B0602 - 33 1

E2 G Valve Plate, Front Cover Assembly # # # - B0602 - 34 1

G Valve Plate, Base # # # - B0602 35 1 PIA

G Valve Plate, Valve # # # - B0602 36 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 37 1 PIA

G Valve Plate, Pin # # # - B0602 - 38 4 PIA

E3 G Gasket, Front Cover # # # - B0602 - 39 1

F G Front Cover Asm. # # # - B0602 - 40 1

G Seal, Front Cover # # # - B0602 - 41 1 PIA

G Snap-ring, Seal Front Cover # # # - B0602 - 42 1 PIA

G Dust Seal, Cloth, Front Cover # # # - B0602 - 43 1 PIA

F1 G Steel Valve, AC Pump # # # - B0602 - 44 1

F2 G Valve Plate, Rear Cover, Assembly # # # - B0602 - 45 1

G Valve Plate, Base # # # - B0602 46 1 PIA

G Valve Plate, Valve # # # - B0602 47 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 48 1 PIA

G Valve Plate, Pin # # # - B0602 - 49 4 PIA

F3 G Gasket, Rear Cover # # # - B0602 - 50 1

G G Rear Cover Asm. # # # - B0602 - 51 1

G O-ring, Plug, Rear Cover # # # - B0602 - 52 1 PIA

G Plug Asm. , Rear Cover # # # - B0602 - 53 1 PIA

H G Magnet Asm., AC Clutch # # # - B0602 - 54 1

G Snap-ring, AC Magnet # # # - B0602 55 1 PIA

G Magnet Asm, Pigtail Connector # # # - B0602 56 1 PIA

$0.06

$0.04

$0.02

$0.03

$0.01

$ 0.02

$0.07

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:27 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

G Magnet Asm, Connector # # # - B0602 57 1 PIA

G Magnet Asm, Liner # # # - B0602 58 1 PIA

I G Clutch Hub Asm. # # # - B0602 - 59 1 I1,I2,I3,I4

G Clutch Hub, Washer, M5 # # # - B0602 60 3 PIA

G Clutch Hub, Rivet Pin, M5 # # # - B0602 61 3 PIA

G Clutch Hub, Rivet Pin, M6 # # # - B0602 62 3 PIA

I1 G Clutch Hub, Splined Hub, Painted # # # - B0602 64 1

I2 G Clutch Hub, Face # # # - B0602 65 1

I3 G Clutch Hub, Isolator,Painted, Asm # # # - B0602 66 1

I4 G Clutch Hub, Cover, Molded # # # - B0602 - 67 1

J G Bracket, Stamped, AC # # # - B0602 - 68 1

K G Clutch Pully Asm # # # - B0602 - 69 1

G Clutch Pully, Friction Material # # # - B0602 - # 1 PIA

G Clutch Pulley, Bearing # # # - B0602 - # 1 PIA

End Item 

Scrap

BASE TECHNOLOG

$0.04

$0.00

$0.13

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:28 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

End Item 

Scrap

BASE TECHNOLOG

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:29 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

End Item 

Scrap

BASE TECHNOLOG

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:30 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

NOTES:

1.

Complete Subsystem Quote 

(Yes/No)

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

the competing technology

End Item 

Scrap

BASE TECHNOLOG

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:31 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

03 Refridgeration/Air Conditioning Subsystem

01 G AC Pump Assembly # # # - B0602 - # 1

G Snap-ring, AC Magnet # # # - B0602 - 02 1 PIA

G Snap-ring, AC Hub # # # - B0602 - 03 1 PIA

G Shim, Clutch Hub # # # - B0602 - 04 2 PIA

G Bolt, AC Clutch Hub Cover # # # - B0602 - 05 3 PIA

G Bolt, Bracket, AC Electrical # # # - B0602 - 06 1 PIA

G Bolt, Short, AC Asm to Hoses # # # - B0602 - # 1 PIA

G Bolt, Long, AC Asm. to Bracket # # # - B0602 - # 1 PIA

A G Center Pump Assembly # # # - B0602 - 07 1

G Spacer, Shaft, Large # # # - B0602 - 08 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 09 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 10 1 PIA

G Bearing, Swash Plate to Piston # # # - B0602 - 11 10 PIA

G Spacer, Shaft, Large # # # - B0602 - 12 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 13 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 14 1 PIA

G Gasket, Pump Housing # # # - B0602 - 15 1 PIA

G Bolt, Front to Rear Housing # # # - B0602 - 16 3 PIA

G Bolt, Front Cover to Rear # # # - B0602 - # 5

B G Rear Pump Housing Assemby # # # - B0602 - 17 1

 G Label, Front Pump Housing # # # - B0602 - 18 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 19 1 PIA

G Dowel, Small, Rear Housing # # # - B0602 - 20 3 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 21 1 PIA

C G Shaft and Swash Plate Asm. # # # - B0602 - 22 1 C1 & C2

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

SG&A

$ -

$6.52

$0.21

$0.52

$0.44

$0.51

Markup

BASE TECHNOLOGY PACK

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

C2 G Swash Plate, AC Pump # # # - B0602 - 24 1 PIA

D G Piston Asm. AC Compressor # # # - B0602 - 25 5

G Piston, AC Compressor # # # - B0602 - 26 1 PIA

G Seal, Piston, AC Compressor # # # - B0602 - 27 1 PIA

E G Front Pump Housing, Asm # # # - B0602 - 28 1

 G Label, Front Pump Housing # # # - B0602 29 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 30 1 PIA

G Dowel, Large Front Housing # # # - B0602 - 31 2 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 32 1 PIA

E1 G Steel Valve, AC Pump # # # - B0602 - 33 1

E2 G Valve Plate, Front Cover Assembly # # # - B0602 - 34 1

G Valve Plate, Base # # # - B0602 35 1 PIA

G Valve Plate, Valve # # # - B0602 36 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 37 1 PIA

G Valve Plate, Pin # # # - B0602 - 38 4 PIA

E3 G Gasket, Front Cover # # # - B0602 - 39 1

F G Front Cover Asm. # # # - B0602 - 40 1

G Seal, Front Cover # # # - B0602 - 41 1 PIA

G Snap-ring, Seal Front Cover # # # - B0602 - 42 1 PIA

G Dust Seal, Cloth, Front Cover # # # - B0602 - 43 1 PIA

F1 G Steel Valve, AC Pump # # # - B0602 - 44 1

F2 G Valve Plate, Rear Cover, Assembly # # # - B0602 - 45 1

G Valve Plate, Base # # # - B0602 46 1 PIA

G Valve Plate, Valve # # # - B0602 47 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 48 1 PIA

G Valve Plate, Pin # # # - B0602 - 49 4 PIA

F3 G Gasket, Rear Cover # # # - B0602 - 50 1

G G Rear Cover Asm. # # # - B0602 - 51 1

G O-ring, Plug, Rear Cover # # # - B0602 - 52 1 PIA

G Plug Asm. , Rear Cover # # # - B0602 - 53 1 PIA

H G Magnet Asm., AC Clutch # # # - B0602 - 54 1

G Snap-ring, AC Magnet # # # - B0602 55 1 PIA

G Magnet Asm, Pigtail Connector # # # - B0602 56 1 PIA

$0.74

$0.59

$0.23

$0.40

$0.18

$ 0.31

$1.02

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:32 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

G Magnet Asm, Connector # # # - B0602 57 1 PIA

G Magnet Asm, Liner # # # - B0602 58 1 PIA

I G Clutch Hub Asm. # # # - B0602 - 59 1 I1,I2,I3,I4

G Clutch Hub, Washer, M5 # # # - B0602 60 3 PIA

G Clutch Hub, Rivet Pin, M5 # # # - B0602 61 3 PIA

G Clutch Hub, Rivet Pin, M6 # # # - B0602 62 3 PIA

I1 G Clutch Hub, Splined Hub, Painted # # # - B0602 64 1

I2 G Clutch Hub, Face # # # - B0602 65 1

I3 G Clutch Hub, Isolator,Painted, Asm # # # - B0602 66 1

I4 G Clutch Hub, Cover, Molded # # # - B0602 - 67 1

J G Bracket, Stamped, AC # # # - B0602 - 68 1

K G Clutch Pully Asm # # # - B0602 - 69 1

G Clutch Pully, Friction Material # # # - B0602 - # 1 PIA

G Clutch Pulley, Bearing # # # - B0602 - # 1 PIA

SG&A

Markup

BASE TECHNOLOGY PACK

$0.65

$0.01

$0.72

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:33 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

SG&A

Markup

BASE TECHNOLOGY PACK

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:34 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

SG&A

Markup

BASE TECHNOLOGY PACK

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:35 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

NOTES:

1.

Complete Subsystem Quote 

(Yes/No)

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

the competing technology

SG&A

Markup

BASE TECHNOLOGY PACK

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:36 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

03 Refridgeration/Air Conditioning Subsystem

01 G AC Pump Assembly # # # - B0602 - # 1

G Snap-ring, AC Magnet # # # - B0602 - 02 1 PIA

G Snap-ring, AC Hub # # # - B0602 - 03 1 PIA

G Shim, Clutch Hub # # # - B0602 - 04 2 PIA

G Bolt, AC Clutch Hub Cover # # # - B0602 - 05 3 PIA

G Bolt, Bracket, AC Electrical # # # - B0602 - 06 1 PIA

G Bolt, Short, AC Asm to Hoses # # # - B0602 - # 1 PIA

G Bolt, Long, AC Asm. to Bracket # # # - B0602 - # 1 PIA

A G Center Pump Assembly # # # - B0602 - 07 1

G Spacer, Shaft, Large # # # - B0602 - 08 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 09 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 10 1 PIA

G Bearing, Swash Plate to Piston # # # - B0602 - 11 10 PIA

G Spacer, Shaft, Large # # # - B0602 - 12 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 13 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 14 1 PIA

G Gasket, Pump Housing # # # - B0602 - 15 1 PIA

G Bolt, Front to Rear Housing # # # - B0602 - 16 3 PIA

G Bolt, Front Cover to Rear # # # - B0602 - # 5

B G Rear Pump Housing Assemby # # # - B0602 - 17 1

 G Label, Front Pump Housing # # # - B0602 - 18 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 19 1 PIA

G Dowel, Small, Rear Housing # # # - B0602 - 20 3 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 21 1 PIA

C G Shaft and Swash Plate Asm. # # # - B0602 - 22 1 C1 & C2

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Profit 

$ -

$5.56

$0.17

$0.45

$0.39

$0.41

Markup

BASE TECHNOLOGY PACKAGE C

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

C2 G Swash Plate, AC Pump # # # - B0602 - 24 1 PIA

D G Piston Asm. AC Compressor # # # - B0602 - 25 5

G Piston, AC Compressor # # # - B0602 - 26 1 PIA

G Seal, Piston, AC Compressor # # # - B0602 - 27 1 PIA

E G Front Pump Housing, Asm # # # - B0602 - 28 1

 G Label, Front Pump Housing # # # - B0602 29 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 30 1 PIA

G Dowel, Large Front Housing # # # - B0602 - 31 2 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 32 1 PIA

E1 G Steel Valve, AC Pump # # # - B0602 - 33 1

E2 G Valve Plate, Front Cover Assembly # # # - B0602 - 34 1

G Valve Plate, Base # # # - B0602 35 1 PIA

G Valve Plate, Valve # # # - B0602 36 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 37 1 PIA

G Valve Plate, Pin # # # - B0602 - 38 4 PIA

E3 G Gasket, Front Cover # # # - B0602 - 39 1

F G Front Cover Asm. # # # - B0602 - 40 1

G Seal, Front Cover # # # - B0602 - 41 1 PIA

G Snap-ring, Seal Front Cover # # # - B0602 - 42 1 PIA

G Dust Seal, Cloth, Front Cover # # # - B0602 - 43 1 PIA

F1 G Steel Valve, AC Pump # # # - B0602 - 44 1

F2 G Valve Plate, Rear Cover, Assembly # # # - B0602 - 45 1

G Valve Plate, Base # # # - B0602 46 1 PIA

G Valve Plate, Valve # # # - B0602 47 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 48 1 PIA

G Valve Plate, Pin # # # - B0602 - 49 4 PIA

F3 G Gasket, Rear Cover # # # - B0602 - 50 1

G G Rear Cover Asm. # # # - B0602 - 51 1

G O-ring, Plug, Rear Cover # # # - B0602 - 52 1 PIA

G Plug Asm. , Rear Cover # # # - B0602 - 53 1 PIA

H G Magnet Asm., AC Clutch # # # - B0602 - 54 1

G Snap-ring, AC Magnet # # # - B0602 55 1 PIA

G Magnet Asm, Pigtail Connector # # # - B0602 56 1 PIA

$0.67

$0.53

$0.19

$0.36

$0.15

$ 0.28

$0.83

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:37 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

G Magnet Asm, Connector # # # - B0602 57 1 PIA

G Magnet Asm, Liner # # # - B0602 58 1 PIA

I G Clutch Hub Asm. # # # - B0602 - 59 1 I1,I2,I3,I4

G Clutch Hub, Washer, M5 # # # - B0602 60 3 PIA

G Clutch Hub, Rivet Pin, M5 # # # - B0602 61 3 PIA

G Clutch Hub, Rivet Pin, M6 # # # - B0602 62 3 PIA

I1 G Clutch Hub, Splined Hub, Painted # # # - B0602 64 1

I2 G Clutch Hub, Face # # # - B0602 65 1

I3 G Clutch Hub, Isolator,Painted, Asm # # # - B0602 66 1

I4 G Clutch Hub, Cover, Molded # # # - B0602 - 67 1

J G Bracket, Stamped, AC # # # - B0602 - 68 1

K G Clutch Pully Asm # # # - B0602 - 69 1

G Clutch Pully, Friction Material # # # - B0602 - # 1 PIA

G Clutch Pulley, Bearing # # # - B0602 - # 1 PIA

Profit 

Markup

BASE TECHNOLOGY PACKAGE C

$0.52

$0.00

$0.59

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:38 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Profit 

Markup

BASE TECHNOLOGY PACKAGE C

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:39 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Profit 

Markup

BASE TECHNOLOGY PACKAGE C

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:40 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

NOTES:

1.

Complete Subsystem Quote 

(Yes/No)

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

the competing technology

Profit 

Markup

BASE TECHNOLOGY PACKAGE C

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:41 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

03 Refridgeration/Air Conditioning Subsystem

01 G AC Pump Assembly # # # - B0602 - # 1

G Snap-ring, AC Magnet # # # - B0602 - 02 1 PIA

G Snap-ring, AC Hub # # # - B0602 - 03 1 PIA

G Shim, Clutch Hub # # # - B0602 - 04 2 PIA

G Bolt, AC Clutch Hub Cover # # # - B0602 - 05 3 PIA

G Bolt, Bracket, AC Electrical # # # - B0602 - 06 1 PIA

G Bolt, Short, AC Asm to Hoses # # # - B0602 - # 1 PIA

G Bolt, Long, AC Asm. to Bracket # # # - B0602 - # 1 PIA

A G Center Pump Assembly # # # - B0602 - 07 1

G Spacer, Shaft, Large # # # - B0602 - 08 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 09 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 10 1 PIA

G Bearing, Swash Plate to Piston # # # - B0602 - 11 10 PIA

G Spacer, Shaft, Large # # # - B0602 - 12 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 13 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 14 1 PIA

G Gasket, Pump Housing # # # - B0602 - 15 1 PIA

G Bolt, Front to Rear Housing # # # - B0602 - 16 3 PIA

G Bolt, Front Cover to Rear # # # - B0602 - # 5

B G Rear Pump Housing Assemby # # # - B0602 - 17 1

 G Label, Front Pump Housing # # # - B0602 - 18 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 19 1 PIA

G Dowel, Small, Rear Housing # # # - B0602 - 20 3 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 21 1 PIA

C G Shaft and Swash Plate Asm. # # # - B0602 - 22 1 C1 & C2

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

ED&TR&D

$ -

$1.89

$0.06

$0.18

$0.16

$0.11

BASE TECHNOLOGY PACKAGE COST INF

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

C2 G Swash Plate, AC Pump # # # - B0602 - 24 1 PIA

D G Piston Asm. AC Compressor # # # - B0602 - 25 5

G Piston, AC Compressor # # # - B0602 - 26 1 PIA

G Seal, Piston, AC Compressor # # # - B0602 - 27 1 PIA

E G Front Pump Housing, Asm # # # - B0602 - 28 1

 G Label, Front Pump Housing # # # - B0602 29 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 30 1 PIA

G Dowel, Large Front Housing # # # - B0602 - 31 2 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 32 1 PIA

E1 G Steel Valve, AC Pump # # # - B0602 - 33 1

E2 G Valve Plate, Front Cover Assembly # # # - B0602 - 34 1

G Valve Plate, Base # # # - B0602 35 1 PIA

G Valve Plate, Valve # # # - B0602 36 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 37 1 PIA

G Valve Plate, Pin # # # - B0602 - 38 4 PIA

E3 G Gasket, Front Cover # # # - B0602 - 39 1

F G Front Cover Asm. # # # - B0602 - 40 1

G Seal, Front Cover # # # - B0602 - 41 1 PIA

G Snap-ring, Seal Front Cover # # # - B0602 - 42 1 PIA

G Dust Seal, Cloth, Front Cover # # # - B0602 - 43 1 PIA

F1 G Steel Valve, AC Pump # # # - B0602 - 44 1

F2 G Valve Plate, Rear Cover, Assembly # # # - B0602 - 45 1

G Valve Plate, Base # # # - B0602 46 1 PIA

G Valve Plate, Valve # # # - B0602 47 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 48 1 PIA

G Valve Plate, Pin # # # - B0602 - 49 4 PIA

F3 G Gasket, Rear Cover # # # - B0602 - 50 1

G G Rear Cover Asm. # # # - B0602 - 51 1

G O-ring, Plug, Rear Cover # # # - B0602 - 52 1 PIA

G Plug Asm. , Rear Cover # # # - B0602 - 53 1 PIA

H G Magnet Asm., AC Clutch # # # - B0602 - 54 1

G Snap-ring, AC Magnet # # # - B0602 55 1 PIA

G Magnet Asm, Pigtail Connector # # # - B0602 56 1 PIA

$0.27

$0.22

$0.05

$0.14

$0.04

$ 0.12

$0.24

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:42 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

G Magnet Asm, Connector # # # - B0602 57 1 PIA

G Magnet Asm, Liner # # # - B0602 58 1 PIA

I G Clutch Hub Asm. # # # - B0602 - 59 1 I1,I2,I3,I4

G Clutch Hub, Washer, M5 # # # - B0602 60 3 PIA

G Clutch Hub, Rivet Pin, M5 # # # - B0602 61 3 PIA

G Clutch Hub, Rivet Pin, M6 # # # - B0602 62 3 PIA

I1 G Clutch Hub, Splined Hub, Painted # # # - B0602 64 1

I2 G Clutch Hub, Face # # # - B0602 65 1

I3 G Clutch Hub, Isolator,Painted, Asm # # # - B0602 66 1

I4 G Clutch Hub, Cover, Molded # # # - B0602 - 67 1

J G Bracket, Stamped, AC # # # - B0602 - 68 1

K G Clutch Pully Asm # # # - B0602 - 69 1

G Clutch Pully, Friction Material # # # - B0602 - # 1 PIA

G Clutch Pulley, Bearing # # # - B0602 - # 1 PIA

ED&TR&D

BASE TECHNOLOGY PACKAGE COST INF

$0.14

$0.00

$0.17

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:43 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

ED&TR&D

BASE TECHNOLOGY PACKAGE COST INF

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:44 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

ED&TR&D

BASE TECHNOLOGY PACKAGE COST INF

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:45 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

NOTES:

1.

Complete Subsystem Quote 

(Yes/No)

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

the competing technology

ED&TR&D

BASE TECHNOLOGY PACKAGE COST INF

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:46 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

03 Refridgeration/Air Conditioning Subsystem

01 G AC Pump Assembly # # # - B0602 - # 1

G Snap-ring, AC Magnet # # # - B0602 - 02 1 PIA

G Snap-ring, AC Hub # # # - B0602 - 03 1 PIA

G Shim, Clutch Hub # # # - B0602 - 04 2 PIA

G Bolt, AC Clutch Hub Cover # # # - B0602 - 05 3 PIA

G Bolt, Bracket, AC Electrical # # # - B0602 - 06 1 PIA

G Bolt, Short, AC Asm to Hoses # # # - B0602 - # 1 PIA

G Bolt, Long, AC Asm. to Bracket # # # - B0602 - # 1 PIA

A G Center Pump Assembly # # # - B0602 - 07 1

G Spacer, Shaft, Large # # # - B0602 - 08 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 09 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 10 1 PIA

G Bearing, Swash Plate to Piston # # # - B0602 - 11 10 PIA

G Spacer, Shaft, Large # # # - B0602 - 12 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 13 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 14 1 PIA

G Gasket, Pump Housing # # # - B0602 - 15 1 PIA

G Bolt, Front to Rear Housing # # # - B0602 - 16 3 PIA

G Bolt, Front Cover to Rear # # # - B0602 - # 5

B G Rear Pump Housing Assemby # # # - B0602 - 17 1

 G Label, Front Pump Housing # # # - B0602 - 18 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 19 1 PIA

G Dowel, Small, Rear Housing # # # - B0602 - 20 3 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 21 1 PIA

C G Shaft and Swash Plate Asm. # # # - B0602 - 22 1 C1 & C2

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

$ -

$ 14.56

$0.46

$1.19

$1.02

$1.11

Total Markup 

Cost 

(Component/ 

Assembly)

BASE TECHNOLOGY PACKAGE COST INFORMA

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

C2 G Swash Plate, AC Pump # # # - B0602 - 24 1 PIA

D G Piston Asm. AC Compressor # # # - B0602 - 25 5

G Piston, AC Compressor # # # - B0602 - 26 1 PIA

G Seal, Piston, AC Compressor # # # - B0602 - 27 1 PIA

E G Front Pump Housing, Asm # # # - B0602 - 28 1

 G Label, Front Pump Housing # # # - B0602 29 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 30 1 PIA

G Dowel, Large Front Housing # # # - B0602 - 31 2 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 32 1 PIA

E1 G Steel Valve, AC Pump # # # - B0602 - 33 1

E2 G Valve Plate, Front Cover Assembly # # # - B0602 - 34 1

G Valve Plate, Base # # # - B0602 35 1 PIA

G Valve Plate, Valve # # # - B0602 36 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 37 1 PIA

G Valve Plate, Pin # # # - B0602 - 38 4 PIA

E3 G Gasket, Front Cover # # # - B0602 - 39 1

F G Front Cover Asm. # # # - B0602 - 40 1

G Seal, Front Cover # # # - B0602 - 41 1 PIA

G Snap-ring, Seal Front Cover # # # - B0602 - 42 1 PIA

G Dust Seal, Cloth, Front Cover # # # - B0602 - 43 1 PIA

F1 G Steel Valve, AC Pump # # # - B0602 - 44 1

F2 G Valve Plate, Rear Cover, Assembly # # # - B0602 - 45 1

G Valve Plate, Base # # # - B0602 46 1 PIA

G Valve Plate, Valve # # # - B0602 47 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 48 1 PIA

G Valve Plate, Pin # # # - B0602 - 49 4 PIA

F3 G Gasket, Rear Cover # # # - B0602 - 50 1

G G Rear Cover Asm. # # # - B0602 - 51 1

G O-ring, Plug, Rear Cover # # # - B0602 - 52 1 PIA

G Plug Asm. , Rear Cover # # # - B0602 - 53 1 PIA

H G Magnet Asm., AC Clutch # # # - B0602 - 54 1

G Snap-ring, AC Magnet # # # - B0602 55 1 PIA

G Magnet Asm, Pigtail Connector # # # - B0602 56 1 PIA

$1.74

$1.38

$0.48

$0.93

$0.39

$ 0.73

$2.16

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:47 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

G Magnet Asm, Connector # # # - B0602 57 1 PIA

G Magnet Asm, Liner # # # - B0602 58 1 PIA

I G Clutch Hub Asm. # # # - B0602 - 59 1 I1,I2,I3,I4

G Clutch Hub, Washer, M5 # # # - B0602 60 3 PIA

G Clutch Hub, Rivet Pin, M5 # # # - B0602 61 3 PIA

G Clutch Hub, Rivet Pin, M6 # # # - B0602 62 3 PIA

I1 G Clutch Hub, Splined Hub, Painted # # # - B0602 64 1

I2 G Clutch Hub, Face # # # - B0602 65 1

I3 G Clutch Hub, Isolator,Painted, Asm # # # - B0602 66 1

I4 G Clutch Hub, Cover, Molded # # # - B0602 - 67 1

J G Bracket, Stamped, AC # # # - B0602 - 68 1

K G Clutch Pully Asm # # # - B0602 - 69 1

G Clutch Pully, Friction Material # # # - B0602 - # 1 PIA

G Clutch Pulley, Bearing # # # - B0602 - # 1 PIA

Total Markup 

Cost 

(Component/ 

Assembly)

BASE TECHNOLOGY PACKAGE COST INFORMA

$1.35

$0.01

$1.61

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:48 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Total Markup 

Cost 

(Component/ 

Assembly)

BASE TECHNOLOGY PACKAGE COST INFORMA

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:49 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Total Markup 

Cost 

(Component/ 

Assembly)

BASE TECHNOLOGY PACKAGE COST INFORMA

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:50 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

NOTES:

1.

Complete Subsystem Quote 

(Yes/No)

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

the competing technology

Total Markup 

Cost 

(Component/ 

Assembly)

BASE TECHNOLOGY PACKAGE COST INFORMA

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:51 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

03 Refridgeration/Air Conditioning Subsystem

01 G AC Pump Assembly # # # - B0602 - # 1

G Snap-ring, AC Magnet # # # - B0602 - 02 1 PIA

G Snap-ring, AC Hub # # # - B0602 - 03 1 PIA

G Shim, Clutch Hub # # # - B0602 - 04 2 PIA

G Bolt, AC Clutch Hub Cover # # # - B0602 - 05 3 PIA

G Bolt, Bracket, AC Electrical # # # - B0602 - 06 1 PIA

G Bolt, Short, AC Asm to Hoses # # # - B0602 - # 1 PIA

G Bolt, Long, AC Asm. to Bracket # # # - B0602 - # 1 PIA

A G Center Pump Assembly # # # - B0602 - 07 1

G Spacer, Shaft, Large # # # - B0602 - 08 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 09 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 10 1 PIA

G Bearing, Swash Plate to Piston # # # - B0602 - 11 10 PIA

G Spacer, Shaft, Large # # # - B0602 - 12 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 13 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 14 1 PIA

G Gasket, Pump Housing # # # - B0602 - 15 1 PIA

G Bolt, Front to Rear Housing # # # - B0602 - 16 3 PIA

G Bolt, Front Cover to Rear # # # - B0602 - # 5

B G Rear Pump Housing Assemby # # # - B0602 - 17 1

 G Label, Front Pump Housing # # # - B0602 - 18 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 19 1 PIA

G Dowel, Small, Rear Housing # # # - B0602 - 20 3 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 21 1 PIA

C G Shaft and Swash Plate Asm. # # # - B0602 - 22 1 C1 & C2

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

$ -

$0.01

$0.01

$0.00

$0.00

$0.00

Total 

Packaging 

Cost 

(Compone

nt/ 

Assembly)

BASE TECHNOLOGY PACKAGE COST INFORMATION

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

C2 G Swash Plate, AC Pump # # # - B0602 - 24 1 PIA

D G Piston Asm. AC Compressor # # # - B0602 - 25 5

G Piston, AC Compressor # # # - B0602 - 26 1 PIA

G Seal, Piston, AC Compressor # # # - B0602 - 27 1 PIA

E G Front Pump Housing, Asm # # # - B0602 - 28 1

 G Label, Front Pump Housing # # # - B0602 29 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 30 1 PIA

G Dowel, Large Front Housing # # # - B0602 - 31 2 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 32 1 PIA

E1 G Steel Valve, AC Pump # # # - B0602 - 33 1

E2 G Valve Plate, Front Cover Assembly # # # - B0602 - 34 1

G Valve Plate, Base # # # - B0602 35 1 PIA

G Valve Plate, Valve # # # - B0602 36 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 37 1 PIA

G Valve Plate, Pin # # # - B0602 - 38 4 PIA

E3 G Gasket, Front Cover # # # - B0602 - 39 1

F G Front Cover Asm. # # # - B0602 - 40 1

G Seal, Front Cover # # # - B0602 - 41 1 PIA

G Snap-ring, Seal Front Cover # # # - B0602 - 42 1 PIA

G Dust Seal, Cloth, Front Cover # # # - B0602 - 43 1 PIA

F1 G Steel Valve, AC Pump # # # - B0602 - 44 1

F2 G Valve Plate, Rear Cover, Assembly # # # - B0602 - 45 1

G Valve Plate, Base # # # - B0602 46 1 PIA

G Valve Plate, Valve # # # - B0602 47 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 48 1 PIA

G Valve Plate, Pin # # # - B0602 - 49 4 PIA

F3 G Gasket, Rear Cover # # # - B0602 - 50 1

G G Rear Cover Asm. # # # - B0602 - 51 1

G O-ring, Plug, Rear Cover # # # - B0602 - 52 1 PIA

G Plug Asm. , Rear Cover # # # - B0602 - 53 1 PIA

H G Magnet Asm., AC Clutch # # # - B0602 - 54 1

G Snap-ring, AC Magnet # # # - B0602 55 1 PIA

G Magnet Asm, Pigtail Connector # # # - B0602 56 1 PIA

$ -

$0.00

$0.00

$0.00

$ -

$ -

$0.00

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:52 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

G Magnet Asm, Connector # # # - B0602 57 1 PIA

G Magnet Asm, Liner # # # - B0602 58 1 PIA

I G Clutch Hub Asm. # # # - B0602 - 59 1 I1,I2,I3,I4

G Clutch Hub, Washer, M5 # # # - B0602 60 3 PIA

G Clutch Hub, Rivet Pin, M5 # # # - B0602 61 3 PIA

G Clutch Hub, Rivet Pin, M6 # # # - B0602 62 3 PIA

I1 G Clutch Hub, Splined Hub, Painted # # # - B0602 64 1

I2 G Clutch Hub, Face # # # - B0602 65 1

I3 G Clutch Hub, Isolator,Painted, Asm # # # - B0602 66 1

I4 G Clutch Hub, Cover, Molded # # # - B0602 - 67 1

J G Bracket, Stamped, AC # # # - B0602 - 68 1

K G Clutch Pully Asm # # # - B0602 - 69 1

G Clutch Pully, Friction Material # # # - B0602 - # 1 PIA

G Clutch Pulley, Bearing # # # - B0602 - # 1 PIA

Total 

Packaging 

Cost 

(Compone

nt/ 

Assembly)

BASE TECHNOLOGY PACKAGE COST INFORMATION

$0.00

$ -

$0.00

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:53 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Total 

Packaging 

Cost 

(Compone

nt/ 

Assembly)

BASE TECHNOLOGY PACKAGE COST INFORMATION

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:54 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Total 

Packaging 

Cost 

(Compone

nt/ 

Assembly)

BASE TECHNOLOGY PACKAGE COST INFORMATION

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:55 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

NOTES:

1.

Complete Subsystem Quote 

(Yes/No)

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

the competing technology

Total 

Packaging 

Cost 

(Compone

nt/ 

Assembly)

BASE TECHNOLOGY PACKAGE COST INFORMATION

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:56 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

03 Refridgeration/Air Conditioning Subsystem

01 G AC Pump Assembly # # # - B0602 - # 1

G Snap-ring, AC Magnet # # # - B0602 - 02 1 PIA

G Snap-ring, AC Hub # # # - B0602 - 03 1 PIA

G Shim, Clutch Hub # # # - B0602 - 04 2 PIA

G Bolt, AC Clutch Hub Cover # # # - B0602 - 05 3 PIA

G Bolt, Bracket, AC Electrical # # # - B0602 - 06 1 PIA

G Bolt, Short, AC Asm to Hoses # # # - B0602 - # 1 PIA

G Bolt, Long, AC Asm. to Bracket # # # - B0602 - # 1 PIA

A G Center Pump Assembly # # # - B0602 - 07 1

G Spacer, Shaft, Large # # # - B0602 - 08 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 09 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 10 1 PIA

G Bearing, Swash Plate to Piston # # # - B0602 - 11 10 PIA

G Spacer, Shaft, Large # # # - B0602 - 12 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 13 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 14 1 PIA

G Gasket, Pump Housing # # # - B0602 - 15 1 PIA

G Bolt, Front to Rear Housing # # # - B0602 - 16 3 PIA

G Bolt, Front Cover to Rear # # # - B0602 - # 5

B G Rear Pump Housing Assemby # # # - B0602 - 17 1

 G Label, Front Pump Housing # # # - B0602 - 18 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 19 1 PIA

G Dowel, Small, Rear Housing # # # - B0602 - 20 3 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 21 1 PIA

C G Shaft and Swash Plate Asm. # # # - B0602 - 22 1 C1 & C2

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

$ -

$ 83.76

$2.30

$7.26

$6.99

$4.94

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLOGY PACKAGE COST INFORMATION

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

C2 G Swash Plate, AC Pump # # # - B0602 - 24 1 PIA

D G Piston Asm. AC Compressor # # # - B0602 - 25 5

G Piston, AC Compressor # # # - B0602 - 26 1 PIA

G Seal, Piston, AC Compressor # # # - B0602 - 27 1 PIA

E G Front Pump Housing, Asm # # # - B0602 - 28 1

 G Label, Front Pump Housing # # # - B0602 29 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 30 1 PIA

G Dowel, Large Front Housing # # # - B0602 - 31 2 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 32 1 PIA

E1 G Steel Valve, AC Pump # # # - B0602 - 33 1

E2 G Valve Plate, Front Cover Assembly # # # - B0602 - 34 1

G Valve Plate, Base # # # - B0602 35 1 PIA

G Valve Plate, Valve # # # - B0602 36 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 37 1 PIA

G Valve Plate, Pin # # # - B0602 - 38 4 PIA

E3 G Gasket, Front Cover # # # - B0602 - 39 1

F G Front Cover Asm. # # # - B0602 - 40 1

G Seal, Front Cover # # # - B0602 - 41 1 PIA

G Snap-ring, Seal Front Cover # # # - B0602 - 42 1 PIA

G Dust Seal, Cloth, Front Cover # # # - B0602 - 43 1 PIA

F1 G Steel Valve, AC Pump # # # - B0602 - 44 1

F2 G Valve Plate, Rear Cover, Assembly # # # - B0602 - 45 1

G Valve Plate, Base # # # - B0602 46 1 PIA

G Valve Plate, Valve # # # - B0602 47 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 48 1 PIA

G Valve Plate, Pin # # # - B0602 - 49 4 PIA

F3 G Gasket, Rear Cover # # # - B0602 - 50 1

G G Rear Cover Asm. # # # - B0602 - 51 1

G O-ring, Plug, Rear Cover # # # - B0602 - 52 1 PIA

G Plug Asm. , Rear Cover # # # - B0602 - 53 1 PIA

H G Magnet Asm., AC Clutch # # # - B0602 - 54 1

G Snap-ring, AC Magnet # # # - B0602 55 1 PIA

G Magnet Asm, Pigtail Connector # # # - B0602 56 1 PIA

$ 12.31

$9.69

$2.27

$6.44

$ 1.81

$ 5.17

$10.23

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:57 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

G Magnet Asm, Connector # # # - B0602 57 1 PIA

G Magnet Asm, Liner # # # - B0602 58 1 PIA

I G Clutch Hub Asm. # # # - B0602 - 59 1 I1,I2,I3,I4

G Clutch Hub, Washer, M5 # # # - B0602 60 3 PIA

G Clutch Hub, Rivet Pin, M5 # # # - B0602 61 3 PIA

G Clutch Hub, Rivet Pin, M6 # # # - B0602 62 3 PIA

I1 G Clutch Hub, Splined Hub, Painted # # # - B0602 64 1

I2 G Clutch Hub, Face # # # - B0602 65 1

I3 G Clutch Hub, Isolator,Painted, Asm # # # - B0602 66 1

I4 G Clutch Hub, Cover, Molded # # # - B0602 - 67 1

J G Bracket, Stamped, AC # # # - B0602 - 68 1

K G Clutch Pully Asm # # # - B0602 - 69 1

G Clutch Pully, Friction Material # # # - B0602 - # 1 PIA

G Clutch Pulley, Bearing # # # - B0602 - # 1 PIA

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLOGY PACKAGE COST INFORMATION

$6.28

$ 0.05

$8.01

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:58 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLOGY PACKAGE COST INFORMATION

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:59 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLOGY PACKAGE COST INFORMATION

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:60 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

NOTES:

1.

Complete Subsystem Quote 

(Yes/No)

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

the competing technology

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLOGY PACKAGE COST INFORMATION

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:61 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

03 Refridgeration/Air Conditioning Subsystem

01 G AC Pump Assembly # # # - B0602 - # 1

G Snap-ring, AC Magnet # # # - B0602 - 02 1 PIA

G Snap-ring, AC Hub # # # - B0602 - 03 1 PIA

G Shim, Clutch Hub # # # - B0602 - 04 2 PIA

G Bolt, AC Clutch Hub Cover # # # - B0602 - 05 3 PIA

G Bolt, Bracket, AC Electrical # # # - B0602 - 06 1 PIA

G Bolt, Short, AC Asm to Hoses # # # - B0602 - # 1 PIA

G Bolt, Long, AC Asm. to Bracket # # # - B0602 - # 1 PIA

A G Center Pump Assembly # # # - B0602 - 07 1

G Spacer, Shaft, Large # # # - B0602 - 08 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 09 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 10 1 PIA

G Bearing, Swash Plate to Piston # # # - B0602 - 11 10 PIA

G Spacer, Shaft, Large # # # - B0602 - 12 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 13 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 14 1 PIA

G Gasket, Pump Housing # # # - B0602 - 15 1 PIA

G Bolt, Front to Rear Housing # # # - B0602 - 16 3 PIA

G Bolt, Front Cover to Rear # # # - B0602 - # 5

B G Rear Pump Housing Assemby # # # - B0602 - 17 1

 G Label, Front Pump Housing # # # - B0602 - 18 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 19 1 PIA

G Dowel, Small, Rear Housing # # # - B0602 - 20 3 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 21 1 PIA

C G Shaft and Swash Plate Asm. # # # - B0602 - 22 1 C1 & C2

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

$ -

$ -

System 

ED&T/R&D

(x1000)

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

C2 G Swash Plate, AC Pump # # # - B0602 - 24 1 PIA

D G Piston Asm. AC Compressor # # # - B0602 - 25 5

G Piston, AC Compressor # # # - B0602 - 26 1 PIA

G Seal, Piston, AC Compressor # # # - B0602 - 27 1 PIA

E G Front Pump Housing, Asm # # # - B0602 - 28 1

 G Label, Front Pump Housing # # # - B0602 29 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 30 1 PIA

G Dowel, Large Front Housing # # # - B0602 - 31 2 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 32 1 PIA

E1 G Steel Valve, AC Pump # # # - B0602 - 33 1

E2 G Valve Plate, Front Cover Assembly # # # - B0602 - 34 1

G Valve Plate, Base # # # - B0602 35 1 PIA

G Valve Plate, Valve # # # - B0602 36 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 37 1 PIA

G Valve Plate, Pin # # # - B0602 - 38 4 PIA

E3 G Gasket, Front Cover # # # - B0602 - 39 1

F G Front Cover Asm. # # # - B0602 - 40 1

G Seal, Front Cover # # # - B0602 - 41 1 PIA

G Snap-ring, Seal Front Cover # # # - B0602 - 42 1 PIA

G Dust Seal, Cloth, Front Cover # # # - B0602 - 43 1 PIA

F1 G Steel Valve, AC Pump # # # - B0602 - 44 1

F2 G Valve Plate, Rear Cover, Assembly # # # - B0602 - 45 1

G Valve Plate, Base # # # - B0602 46 1 PIA

G Valve Plate, Valve # # # - B0602 47 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 48 1 PIA

G Valve Plate, Pin # # # - B0602 - 49 4 PIA

F3 G Gasket, Rear Cover # # # - B0602 - 50 1

G G Rear Cover Asm. # # # - B0602 - 51 1

G O-ring, Plug, Rear Cover # # # - B0602 - 52 1 PIA

G Plug Asm. , Rear Cover # # # - B0602 - 53 1 PIA

H G Magnet Asm., AC Clutch # # # - B0602 - 54 1

G Snap-ring, AC Magnet # # # - B0602 55 1 PIA

G Magnet Asm, Pigtail Connector # # # - B0602 56 1 PIA

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:62 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

G Magnet Asm, Connector # # # - B0602 57 1 PIA

G Magnet Asm, Liner # # # - B0602 58 1 PIA

I G Clutch Hub Asm. # # # - B0602 - 59 1 I1,I2,I3,I4

G Clutch Hub, Washer, M5 # # # - B0602 60 3 PIA

G Clutch Hub, Rivet Pin, M5 # # # - B0602 61 3 PIA

G Clutch Hub, Rivet Pin, M6 # # # - B0602 62 3 PIA

I1 G Clutch Hub, Splined Hub, Painted # # # - B0602 64 1

I2 G Clutch Hub, Face # # # - B0602 65 1

I3 G Clutch Hub, Isolator,Painted, Asm # # # - B0602 66 1

I4 G Clutch Hub, Cover, Molded # # # - B0602 - 67 1

J G Bracket, Stamped, AC # # # - B0602 - 68 1

K G Clutch Pully Asm # # # - B0602 - 69 1

G Clutch Pully, Friction Material # # # - B0602 - # 1 PIA

G Clutch Pulley, Bearing # # # - B0602 - # 1 PIA

System 

ED&T/R&D

(x1000)

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:63 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

System 

ED&T/R&D

(x1000)

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:64 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

System 

ED&T/R&D

(x1000)

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:65 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

NOTES:

1.

Complete Subsystem Quote 

(Yes/No)

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

the competing technology

System 

ED&T/R&D

(x1000)

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:66 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

03 Refridgeration/Air Conditioning Subsystem

01 G AC Pump Assembly # # # - B0602 - # 1

G Snap-ring, AC Magnet # # # - B0602 - 02 1 PIA

G Snap-ring, AC Hub # # # - B0602 - 03 1 PIA

G Shim, Clutch Hub # # # - B0602 - 04 2 PIA

G Bolt, AC Clutch Hub Cover # # # - B0602 - 05 3 PIA

G Bolt, Bracket, AC Electrical # # # - B0602 - 06 1 PIA

G Bolt, Short, AC Asm to Hoses # # # - B0602 - # 1 PIA

G Bolt, Long, AC Asm. to Bracket # # # - B0602 - # 1 PIA

A G Center Pump Assembly # # # - B0602 - 07 1

G Spacer, Shaft, Large # # # - B0602 - 08 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 09 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 10 1 PIA

G Bearing, Swash Plate to Piston # # # - B0602 - 11 10 PIA

G Spacer, Shaft, Large # # # - B0602 - 12 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 13 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 14 1 PIA

G Gasket, Pump Housing # # # - B0602 - 15 1 PIA

G Bolt, Front to Rear Housing # # # - B0602 - 16 3 PIA

G Bolt, Front Cover to Rear # # # - B0602 - # 5

B G Rear Pump Housing Assemby # # # - B0602 - 17 1

 G Label, Front Pump Housing # # # - B0602 - 18 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 19 1 PIA

G Dowel, Small, Rear Housing # # # - B0602 - 20 3 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 21 1 PIA

C G Shaft and Swash Plate Asm. # # # - B0602 - 22 1 C1 & C2

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

$ -

$ -

Tooling 

(x1000)

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

C2 G Swash Plate, AC Pump # # # - B0602 - 24 1 PIA

D G Piston Asm. AC Compressor # # # - B0602 - 25 5

G Piston, AC Compressor # # # - B0602 - 26 1 PIA

G Seal, Piston, AC Compressor # # # - B0602 - 27 1 PIA

E G Front Pump Housing, Asm # # # - B0602 - 28 1

 G Label, Front Pump Housing # # # - B0602 29 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 30 1 PIA

G Dowel, Large Front Housing # # # - B0602 - 31 2 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 32 1 PIA

E1 G Steel Valve, AC Pump # # # - B0602 - 33 1

E2 G Valve Plate, Front Cover Assembly # # # - B0602 - 34 1

G Valve Plate, Base # # # - B0602 35 1 PIA

G Valve Plate, Valve # # # - B0602 36 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 37 1 PIA

G Valve Plate, Pin # # # - B0602 - 38 4 PIA

E3 G Gasket, Front Cover # # # - B0602 - 39 1

F G Front Cover Asm. # # # - B0602 - 40 1

G Seal, Front Cover # # # - B0602 - 41 1 PIA

G Snap-ring, Seal Front Cover # # # - B0602 - 42 1 PIA

G Dust Seal, Cloth, Front Cover # # # - B0602 - 43 1 PIA

F1 G Steel Valve, AC Pump # # # - B0602 - 44 1

F2 G Valve Plate, Rear Cover, Assembly # # # - B0602 - 45 1

G Valve Plate, Base # # # - B0602 46 1 PIA

G Valve Plate, Valve # # # - B0602 47 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 48 1 PIA

G Valve Plate, Pin # # # - B0602 - 49 4 PIA

F3 G Gasket, Rear Cover # # # - B0602 - 50 1

G G Rear Cover Asm. # # # - B0602 - 51 1

G O-ring, Plug, Rear Cover # # # - B0602 - 52 1 PIA

G Plug Asm. , Rear Cover # # # - B0602 - 53 1 PIA

H G Magnet Asm., AC Clutch # # # - B0602 - 54 1

G Snap-ring, AC Magnet # # # - B0602 55 1 PIA

G Magnet Asm, Pigtail Connector # # # - B0602 56 1 PIA

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:67 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

G Magnet Asm, Connector # # # - B0602 57 1 PIA

G Magnet Asm, Liner # # # - B0602 58 1 PIA

I G Clutch Hub Asm. # # # - B0602 - 59 1 I1,I2,I3,I4

G Clutch Hub, Washer, M5 # # # - B0602 60 3 PIA

G Clutch Hub, Rivet Pin, M5 # # # - B0602 61 3 PIA

G Clutch Hub, Rivet Pin, M6 # # # - B0602 62 3 PIA

I1 G Clutch Hub, Splined Hub, Painted # # # - B0602 64 1

I2 G Clutch Hub, Face # # # - B0602 65 1

I3 G Clutch Hub, Isolator,Painted, Asm # # # - B0602 66 1

I4 G Clutch Hub, Cover, Molded # # # - B0602 - 67 1

J G Bracket, Stamped, AC # # # - B0602 - 68 1

K G Clutch Pully Asm # # # - B0602 - 69 1

G Clutch Pully, Friction Material # # # - B0602 - # 1 PIA

G Clutch Pulley, Bearing # # # - B0602 - # 1 PIA

Tooling 

(x1000)

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:68 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Tooling 

(x1000)

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:69 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Tooling 

(x1000)

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:70 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

NOTES:

1.

Complete Subsystem Quote 

(Yes/No)

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

the competing technology

Tooling 

(x1000)

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:71 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

03 Refridgeration/Air Conditioning Subsystem

01 G AC Pump Assembly # # # - B0602 - # 1

G Snap-ring, AC Magnet # # # - B0602 - 02 1 PIA

G Snap-ring, AC Hub # # # - B0602 - 03 1 PIA

G Shim, Clutch Hub # # # - B0602 - 04 2 PIA

G Bolt, AC Clutch Hub Cover # # # - B0602 - 05 3 PIA

G Bolt, Bracket, AC Electrical # # # - B0602 - 06 1 PIA

G Bolt, Short, AC Asm to Hoses # # # - B0602 - # 1 PIA

G Bolt, Long, AC Asm. to Bracket # # # - B0602 - # 1 PIA

A G Center Pump Assembly # # # - B0602 - 07 1

G Spacer, Shaft, Large # # # - B0602 - 08 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 09 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 10 1 PIA

G Bearing, Swash Plate to Piston # # # - B0602 - 11 10 PIA

G Spacer, Shaft, Large # # # - B0602 - 12 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 13 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 14 1 PIA

G Gasket, Pump Housing # # # - B0602 - 15 1 PIA

G Bolt, Front to Rear Housing # # # - B0602 - 16 3 PIA

G Bolt, Front Cover to Rear # # # - B0602 - # 5

B G Rear Pump Housing Assemby # # # - B0602 - 17 1

 G Label, Front Pump Housing # # # - B0602 - 18 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 19 1 PIA

G Dowel, Small, Rear Housing # # # - B0602 - 20 3 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 21 1 PIA

C G Shaft and Swash Plate Asm. # # # - B0602 - 22 1 C1 & C2

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

$ -

$ -

Investment

(X1000)

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

C2 G Swash Plate, AC Pump # # # - B0602 - 24 1 PIA

D G Piston Asm. AC Compressor # # # - B0602 - 25 5

G Piston, AC Compressor # # # - B0602 - 26 1 PIA

G Seal, Piston, AC Compressor # # # - B0602 - 27 1 PIA

E G Front Pump Housing, Asm # # # - B0602 - 28 1

 G Label, Front Pump Housing # # # - B0602 29 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 30 1 PIA

G Dowel, Large Front Housing # # # - B0602 - 31 2 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 32 1 PIA

E1 G Steel Valve, AC Pump # # # - B0602 - 33 1

E2 G Valve Plate, Front Cover Assembly # # # - B0602 - 34 1

G Valve Plate, Base # # # - B0602 35 1 PIA

G Valve Plate, Valve # # # - B0602 36 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 37 1 PIA

G Valve Plate, Pin # # # - B0602 - 38 4 PIA

E3 G Gasket, Front Cover # # # - B0602 - 39 1

F G Front Cover Asm. # # # - B0602 - 40 1

G Seal, Front Cover # # # - B0602 - 41 1 PIA

G Snap-ring, Seal Front Cover # # # - B0602 - 42 1 PIA

G Dust Seal, Cloth, Front Cover # # # - B0602 - 43 1 PIA

F1 G Steel Valve, AC Pump # # # - B0602 - 44 1

F2 G Valve Plate, Rear Cover, Assembly # # # - B0602 - 45 1

G Valve Plate, Base # # # - B0602 46 1 PIA

G Valve Plate, Valve # # # - B0602 47 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 48 1 PIA

G Valve Plate, Pin # # # - B0602 - 49 4 PIA

F3 G Gasket, Rear Cover # # # - B0602 - 50 1

G G Rear Cover Asm. # # # - B0602 - 51 1

G O-ring, Plug, Rear Cover # # # - B0602 - 52 1 PIA

G Plug Asm. , Rear Cover # # # - B0602 - 53 1 PIA

H G Magnet Asm., AC Clutch # # # - B0602 - 54 1

G Snap-ring, AC Magnet # # # - B0602 55 1 PIA

G Magnet Asm, Pigtail Connector # # # - B0602 56 1 PIA

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:72 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

G Magnet Asm, Connector # # # - B0602 57 1 PIA

G Magnet Asm, Liner # # # - B0602 58 1 PIA

I G Clutch Hub Asm. # # # - B0602 - 59 1 I1,I2,I3,I4

G Clutch Hub, Washer, M5 # # # - B0602 60 3 PIA

G Clutch Hub, Rivet Pin, M5 # # # - B0602 61 3 PIA

G Clutch Hub, Rivet Pin, M6 # # # - B0602 62 3 PIA

I1 G Clutch Hub, Splined Hub, Painted # # # - B0602 64 1

I2 G Clutch Hub, Face # # # - B0602 65 1

I3 G Clutch Hub, Isolator,Painted, Asm # # # - B0602 66 1

I4 G Clutch Hub, Cover, Molded # # # - B0602 - 67 1

J G Bracket, Stamped, AC # # # - B0602 - 68 1

K G Clutch Pully Asm # # # - B0602 - 69 1

G Clutch Pully, Friction Material # # # - B0602 - # 1 PIA

G Clutch Pulley, Bearing # # # - B0602 - # 1 PIA

Investment

(X1000)

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:73 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Investment

(X1000)

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:74 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

Investment

(X1000)

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:75 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

NOTES:

1.

Complete Subsystem Quote 

(Yes/No)

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

the competing technology

Investment

(X1000)

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:76 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

03 Refridgeration/Air Conditioning Subsystem

01 G AC Pump Assembly # # # - B0602 - # 1

G Snap-ring, AC Magnet # # # - B0602 - 02 1 PIA

G Snap-ring, AC Hub # # # - B0602 - 03 1 PIA

G Shim, Clutch Hub # # # - B0602 - 04 2 PIA

G Bolt, AC Clutch Hub Cover # # # - B0602 - 05 3 PIA

G Bolt, Bracket, AC Electrical # # # - B0602 - 06 1 PIA

G Bolt, Short, AC Asm to Hoses # # # - B0602 - # 1 PIA

G Bolt, Long, AC Asm. to Bracket # # # - B0602 - # 1 PIA

A G Center Pump Assembly # # # - B0602 - 07 1

G Spacer, Shaft, Large # # # - B0602 - 08 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 09 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 10 1 PIA

G Bearing, Swash Plate to Piston # # # - B0602 - 11 10 PIA

G Spacer, Shaft, Large # # # - B0602 - 12 1 PIA

G Thrust Bearing, Shaft # # # - B0602 - 13 1 PIA

G Spacer, Shaft, Small # # # - B0602 - 14 1 PIA

G Gasket, Pump Housing # # # - B0602 - 15 1 PIA

G Bolt, Front to Rear Housing # # # - B0602 - 16 3 PIA

G Bolt, Front Cover to Rear # # # - B0602 - # 5

B G Rear Pump Housing Assemby # # # - B0602 - 17 1

 G Label, Front Pump Housing # # # - B0602 - 18 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 19 1 PIA

G Dowel, Small, Rear Housing # # # - B0602 - 20 3 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 21 1 PIA

C G Shaft and Swash Plate Asm. # # # - B0602 - 22 1 C1 & C2

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

C1 G Shaft, AC Pump # # # - B0602 - 23 1 PIA

C2 G Swash Plate, AC Pump # # # - B0602 - 24 1 PIA

D G Piston Asm. AC Compressor # # # - B0602 - 25 5

G Piston, AC Compressor # # # - B0602 - 26 1 PIA

G Seal, Piston, AC Compressor # # # - B0602 - 27 1 PIA

E G Front Pump Housing, Asm # # # - B0602 - 28 1

 G Label, Front Pump Housing # # # - B0602 29 1 PIA

G Bearing, Needle, AC Pump # # # - B0602 - 30 1 PIA

G Dowel, Large Front Housing # # # - B0602 - 31 2 PIA

G O Ring, Housing, AC Pump # # # - B0602 - 32 1 PIA

E1 G Steel Valve, AC Pump # # # - B0602 - 33 1

E2 G Valve Plate, Front Cover Assembly # # # - B0602 - 34 1

G Valve Plate, Base # # # - B0602 35 1 PIA

G Valve Plate, Valve # # # - B0602 36 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 37 1 PIA

G Valve Plate, Pin # # # - B0602 - 38 4 PIA

E3 G Gasket, Front Cover # # # - B0602 - 39 1

F G Front Cover Asm. # # # - B0602 - 40 1

G Seal, Front Cover # # # - B0602 - 41 1 PIA

G Snap-ring, Seal Front Cover # # # - B0602 - 42 1 PIA

G Dust Seal, Cloth, Front Cover # # # - B0602 - 43 1 PIA

F1 G Steel Valve, AC Pump # # # - B0602 - 44 1

F2 G Valve Plate, Rear Cover, Assembly # # # - B0602 - 45 1

G Valve Plate, Base # # # - B0602 46 1 PIA

G Valve Plate, Valve # # # - B0602 47 1 PIA

G Steel Valve, Top, Stamp # # # - B0602 48 1 PIA

G Valve Plate, Pin # # # - B0602 - 49 4 PIA

F3 G Gasket, Rear Cover # # # - B0602 - 50 1

G G Rear Cover Asm. # # # - B0602 - 51 1

G O-ring, Plug, Rear Cover # # # - B0602 - 52 1 PIA

G Plug Asm. , Rear Cover # # # - B0602 - 53 1 PIA

H G Magnet Asm., AC Clutch # # # - B0602 - 54 1

G Snap-ring, AC Magnet # # # - B0602 55 1 PIA

G Magnet Asm, Pigtail Connector # # # - B0602 56 1 PIA

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:77 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

G Magnet Asm, Connector # # # - B0602 57 1 PIA

G Magnet Asm, Liner # # # - B0602 58 1 PIA

I G Clutch Hub Asm. # # # - B0602 - 59 1 I1,I2,I3,I4

G Clutch Hub, Washer, M5 # # # - B0602 60 3 PIA

G Clutch Hub, Rivet Pin, M5 # # # - B0602 61 3 PIA

G Clutch Hub, Rivet Pin, M6 # # # - B0602 62 3 PIA

I1 G Clutch Hub, Splined Hub, Painted # # # - B0602 64 1

I2 G Clutch Hub, Face # # # - B0602 65 1

I3 G Clutch Hub, Isolator,Painted, Asm # # # - B0602 66 1

I4 G Clutch Hub, Cover, Molded # # # - B0602 - 67 1

J G Bracket, Stamped, AC # # # - B0602 - 68 1

K G Clutch Pully Asm # # # - B0602 - 69 1

G Clutch Pully, Friction Material # # # - B0602 - # 1 PIA

G Clutch Pulley, Bearing # # # - B0602 - # 1 PIA

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:78 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:79 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:80 of 80 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY GENERAL PART INFORMATION:

 3.0L V4, DOHC, NA, PFI ENGINE

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: B0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

NOTES:

1.

Complete Subsystem Quote 

(Yes/No)

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

the competing technology

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411