Page:1 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

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

021200 Transmission Cooling Subsystem

1 00 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

02 # 00 - B0502 - 01

02 # 00 - B0502 - **

2 01 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

02 # 01 - B0502 - 01

02 # 01 - B0502 - **

Name/Description Part Number

Total 

Packaging 

Cost 

(Component

/ Assembly)

System 

ED&T/R&D

(x1000)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup Net 

Component/ 

Assembly 

Cost Impact to 

S

OEM

ubassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

Assembly

Assembly of Cooling Subsystem 

Water Pumps

Technology Level: Electrical Versus Mechanical Brake Booster Assembly

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

Study Case#: N0502 (N=New, B=Base, ) 05=Technology Package, 02=Vehicle Class

Technology Level: Power-Split HEV Technology

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

Study Case#: B0502 (N=New, B=Base, ) 05=Technology Package, 02=Vehicle Class

3 02

02 # 02 - B0502 - 01

02 # 02 - B0502 - **

4 04 $ 4.89 $ 8.99 $ 9.19 $ 23.06 $ 0.19 $ 2.92 $ 2.38 $ 0.64 $ 6.14 $ - $ 29.20 $ -

A G - Trans Cooler System 02 # 04 - B0502 - 01 1 Full 1 $ 4.89 $ 8.99 $ 9.19 $ 23.06 $ 0.19 $ 2.92 $ 2.38 $ 0.64 $ 6.14 $ - $ 29.20

02 # 04 - B0502 - **

5 05 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

02 # 05 - B0502 - 01

02 # 05 - B0502 - **

6 06 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

02 # 06 - B0502 - 01

02 # 06 - B0502 - **

7 65 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

02 # 65 - B0502 - 01

02 # 65 - B0502 - **

9 70 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

02 # 70 - B0502 - 01

02 # 70 - B0502 - **

10 75 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

02 # 75 - B0502 - 01

02 # 75 - B0502 - **

11 80 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

02 # 80 - B0502 - 01

02 # 80 - B0502 - **

12 85 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

02 # 85 - B0502 - 01

Thermostat Housings

Heat Exchangers

Pressure Regulators

Adaptors

Pipes, Hoses, Ducting

Expansion Tanks

Brackets

Boltings

Sealing Elements

02 # 85 - B0502 - 01

02 # 85 - B0502 - **

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:2 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

Name/Description Part Number

Total 

Packaging 

Cost 

(Component

/ Assembly)

System 

ED&T/R&D

(x1000)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup Net 

Component/ 

Assembly 

Cost Impact to 

S

OEM

ubassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

Assembly

Technology Level: Electrical Versus Mechanical Brake Booster Assembly

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

Study Case#: N0502 (N=New, B=Base, ) 05=Technology Package, 02=Vehicle Class

Technology Level: Power-Split HEV Technology

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

Study Case#: B0502 (N=New, B=Base, ) 05=Technology Package, 02=Vehicle Class

13 90 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

02 # 90 - B0502 - 01

02 # 90 - B0502 - **

14 95 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

02 # 95 - B0502 - 01

02 # 95 - B0502 - **

15 99 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

02 # 99 - B0502 - 01

02 # 99 - B0502 - **

Miscellaneous

Bearings Elements Misc

Tools

$ 4.89 $ 8.99 $ 9.19 $ 23.06 $ 0.19 $ 2.92 $ 2.38 $ 0.64 $ 6.14 $ - $ 29.20 $ -

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

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:3 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

021200 Transmission Cooling Subsystem

1 00

02 # 00 - B0502 - 01

02 # 00 - B0502 - **

2 01

02 # 01 - B0502 - 01

02 # 01 - B0502 - **

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

QTY/ Subsystem

Notes

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Subassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

Assembly

Assembly of Cooling Subsystem 

Water Pumps

Technology Level: Electrical Versus Mechanical Brake Booster Assembly

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

Study Case#: N0502 (N=New, B=Base, ) 05=Technology Package, 02=Vehicle Class

Technology Level: Power-Split HEV Technology

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

Study Case#: B0502 (N=New, B=Base, ) 05=Technology Package, 02=Vehicle Class

$ - $ -

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

3 02

02 # 02 - B0502 - 01

02 # 02 - B0502 - **

4 04

A G - Trans Cooler System 02 # 04 - B0502 - 01 1 Full 1

02 # 04 - B0502 - **

5 05

02 # 05 - B0502 - 01

02 # 05 - B0502 - **

6 06

02 # 06 - B0502 - 01

02 # 06 - B0502 - **

7 65

02 # 65 - B0502 - 01

02 # 65 - B0502 - **

9 70

02 # 70 - B0502 - 01

02 # 70 - B0502 - **

10 75

02 # 75 - B0502 - 01

02 # 75 - B0502 - **

11 80

02 # 80 - B0502 - 01

02 # 80 - B0502 - **

12 85

02 # 85 - B0502 - 01

Thermostat Housings

Heat Exchangers

Pressure Regulators

Adaptors

Pipes, Hoses, Ducting

Expansion Tanks

Brackets

Boltings

Sealing Elements

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

02 # 85 - B0502 - 01

02 # 85 - B0502 - **

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:4 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

QTY/ Subsystem

Notes

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Subassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

Assembly

Technology Level: Electrical Versus Mechanical Brake Booster Assembly

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

Study Case#: N0502 (N=New, B=Base, ) 05=Technology Package, 02=Vehicle Class

Technology Level: Power-Split HEV Technology

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

Study Case#: B0502 (N=New, B=Base, ) 05=Technology Package, 02=Vehicle Class

13 90

02 # 90 - B0502 - 01

02 # 90 - B0502 - **

14 95

02 # 95 - B0502 - 01

02 # 95 - B0502 - **

15 99

02 # 99 - B0502 - 01

02 # 99 - B0502 - **

Miscellaneous

Bearings Elements Misc

Tools

Investment

(X1000)

Tooling 

(x1000)

$ - $ -

$ - $ -

$ - $ -

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

$ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

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

Study Case#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: G Trans Cooler System Part Number: 021204-B0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 1.1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

Costs Broken Out In

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

Parallel HEV Technology 

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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 G Closeout Plate, Exchanger Core, Stamped 021204-B0502-01 1 Stamp T2/T3 Stamp/Form, MSMC Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS 2118 0.5 1 1 0.038 $0.84 $42.73 $42.91 $42.91 $0.03 $0.01 $0.02 $0.06 0.50% 6.50% 6.00% 1.00% 14.00% $0.01 $0.07 $0.07 $0.03

4 G Inner Plate, Exchanger Core, Stamped 021204-B0502-02 8 Stamp T2/T3 Stamp/Form, MSMC Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS 2000 0.5 1 1 0.038 $0.84 $42.73 $42.91 $42.91 $0.03 $0.01 $0.02 $0.06 0.50% 6.50% 6.00% 1.00% 14.00% $0.01 $0.07 $0.58 $0.26

5 G Upper Plate, Exchanger Core, Stamped 021204-B0502-03 1 Stamp T2/T3 Stamp/Form, MSMC Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS 2000 0.5 1 1 0.038 $0.84 $42.73 $42.91 $42.91 $0.03 $0.01 $0.02 $0.06 0.50% 6.50% 6.00% 1.00% 14.00% $0.01 $0.07 $0.07 $0.03

6 G Fin Baffles, Exchanger Core, Roll Formed 021204-B0502-04 5 Roll Form T2/T3 Stamp/Form, MSMC Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS 4500 0.5 1 1 0.0080 $0.84 $42.73 $42.91 $42.91 $0.01 $0.00 $0.01 $0.02 0.50% 6.50% 6.00% 1.00% 14.00% $0.00 $0.02 $0.12 $0.03

7 G Exchanger Core Asm, Trans Cooler 021204-B0502-05 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 144 1.5 3 1 0.000 $0.00 $38.55 $15.00 $45.00 $0.00 $0.40 $0.31 $0.71 0.30% 6.00% 4.00% 0.00% 10.30% $0.07 $0.79 $0.79 $0.00

8 G Fitting, Exchanger Asm 021204-B0502-06 1 Debur T2/T3 CNC Milling, SSLC Not Applicable Grinding/Polishing Operator Grinding, SS 327 1 1 1 0.000 $0.00 $42.14 $45.00 $45.00 $0.00 $0.13 $0.14 $0.27 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.29 $0.29 $0.00

9 021204-B0502-06A 1 Machine T2/T3 CNC Turning, SSLC Aluminum-4032, Bar CNC Operator CNC Machining, LC 113 1.5 3 1 0.1232 $1.44 $36.98 $30.38 $91.14 $0.18 $0.49 $0.81 $1.48 0.30% 6.00% 4.00% 0.00% 10.30% $0.15 $1.63 $1.63 $0.18

10 G Exchanger Base Plate 021204-B0502-07 1 Stamp T2/T3 Stamp/Form, MSMC Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals 5143 0.5 1 1 0.062 $0.84 $42.73 $15.50 $15.50 $0.05 $0.00 $0.00 $0.06 0.50% 6.50% 6.00% 1.00% 14.00% $0.01 $0.07 $0.07 $0.05

11 G Exchanger Asm, Trans Cooler 021204-B0502-08 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 189 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.20 $0.08 $0.28 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.31 $0.31 $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#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: G Trans Cooler System Part Number: 021204-B0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Parallel HEV Technology 

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

12 021204-B0502-08A 1 Oven Braze T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator T5-Al380, SMS 129 1.5 1 1 0.000 $0.00 $47.72 $10.17 $10.17 $0.00 $0.56 $0.08 $0.64 0.30% 6.00% 4.00% 0.00% 10.30% $0.07 $0.70 $0.70 $0.00

13 021204-B0502-08B 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LC 277 0.25 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.03 $0.04 $0.07 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.08 $0.08 $0.00

14 G Trans Exchanger,Radiator Mount 021204-B0502-08C 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 212 1 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.18 $0.14 $0.32 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.36 $0.36 $0.00

15 G Retainer, Line to Line 021204-B0502-09 2 Mold T2/T3 Inject. Mold, SSLC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 2769 1 1 1 0.001 $1.54 $41.48 $16.39 $16.39 $0.00 $0.01 $0.01 $0.02 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.02 $0.05 $0.00

16 G Trans Cooler System 021204-B0502-10 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 125 2 4 1 0.000 $0.00 $38.55 $15.00 $60.00 $0.00 $0.62 $0.48 $1.09 0.30% 6.00% 4.00% 0.00% 10.30% $0.11 $1.21 $1.21 $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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

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

2 G O-ring, Trans Exchanger Asm. 021204-B0502-11 2 S $0.00 $0.05 $0.00 $0.10 $0.10

3 G Nut, Exchanger Asm 021204-B0502-12 2 S $0.00 $0.06 $0.00 $0.12 $0.12

"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: 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#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: G Trans Cooler System Part Number: 021204-B0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Parallel HEV Technology 

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

4 G Retainer, Line to Line 021204-B0502-13 2 S $0.00 $0.00 $0.00 $0.00 $0.00

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

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

7 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

"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.

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

$0.81

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

Mark-up $6.56

T1 or OEM Total Manufacturing Cost: $0.81 $2.78 $2.35 $5.94 $0.02 $0.35 $0.24 $0.01 $0.62 $6.56

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 $0.43 $0.39 $0.16 $1.02

Base Cost Impact to Vehicle: $0.81 $2.78 $2.35 $5.94 $0.05 $0.77 $0.64 $0.17 $1.63 $7.57 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $7.57

3

1

Notes: 

a) Items 1,2, & 3 must a

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

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#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: G Trans Cooler System Part Number: 021204-B0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Parallel HEV Technology 

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

Packaging 

Cost per 

Piece

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: 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! - - - - 1.1 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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

G Closeout Plate, Exchanger Core, Stamped 021204-B0502-01

G Inner Plate, Exchanger Core, Stamped 021204-B0502-02

G Upper Plate, Exchanger Core, Stamped 021204-B0502-03

G Fin Baffles, Exchanger Core, Roll Formed 021204-B0502-04

G Exchanger Core Asm, Trans Cooler 021204-B0502-05

G Fitting, Exchanger Asm 021204-B0502-06

021204-B0502-06A

G Exchanger Base Plate 021204-B0502-07

G Exchanger Asm, Trans Cooler 021204-B0502-08

$0.01 $0.02 $0.06 $0.00 $0.00 $0.00 $0.00 $0.01 200-400 ton progressive die 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1.7 1 1 1.7 1.0 1.0

$0.09 $0.17 $0.51 $0.00 $0.03 $0.03 $0.01 $0.07 200-400 ton progressive die 5 2 10 100 47 4700 766 4.70 85% 901 4.00 1.8 1 1 1.8 1.0 1.0

$0.01 $0.02 $0.06 $0.00 $0.00 $0.00 $0.00 $0.01 200-400 ton progressive die 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1.8 1 1 1.8 1.0 1.0

$0.02 $0.05 $0.11 $0.00 $0.01 $0.01 $0.00 $0.01 Roll Form 5 2 10 100 47 4700 479 7.52 85% 563 6.39 0.8 1 1 0.8 1.0 1.0

$0.40 $0.31 $0.71 $0.00 $0.04 $0.03 $0.00 $0.07 Stack 8 Tubes and 5 fins 5 2 10 100 47 4700 96 37.60 85% 113 31.96 74.8 1 1 74.8 1.0 3.0

$0.13 $0.14 $0.27 $0.00 $0.02 $0.01 $0.00 $0.03 Debur 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 1 1 11 1.0 1.0

$0.49 $0.81 $1.48 $0.00 $0.09 $0.06 $0.00 $0.15 CNC Turning 2 Axis SL-10 1.75 5 2 10 100 47 4700 96 37.60 85% 113 31.96 96 14 1 96 1.0 3.0

$0.00 $0.00 $0.06 $0.00 $0.00 $0.00 $0.00 $0.01 0-60 ton progressive die 5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.7 1 1 0.7 1.0 1.0

$0.20 $0.08 $0.28 $0.00 $0.02 $0.01 $0.00 $0.03 Place o-rings in place 5 2 10 100 47 4700 96 37.60 85% 113 31.96 19 1 1 19 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.

021204-B0502-08A

021204-B0502-08B

G Trans Exchanger,Radiator Mount 021204-B0502-08C

G Retainer, Line to Line 021204-B0502-09

G Trans Cooler System 021204-B0502-10

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

$0.56 $0.08 $0.64 $0.00 $0.04 $0.03 $0.00 $0.07 Oven braze 5 2 10 100 47 4700 96 37.60 85% 113 31.96 28 1 1 28 1.0 1.0

$0.03 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00 $0.01

Batch Wash

5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0

$0.18 $0.14 $0.32 $0.00 $0.02 $0.01 $0.00 $0.03 Add nuts to exchanger 5 2 10 100 47 4700 96 37.60 85% 113 31.96 34 1 1 34 1.0 2.0

$0.03 $0.01 $0.04 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 ton , 8 cavity mold 5 2 10 100 47 4700 191 18.80 85% 225 15.98 1.3 1 8 10.4 1.0 1.0

$0.62 $0.48 $1.09 $0.00 $0.07 $0.04 $0.00 $0.11 Exchanger and lines mounted on FEM.Screw exchanger line in trans exchanger radiator. Press in Xmas 

tree clips. Mate trans and FEM lines. Press together and connect line to line retainers 5 2 10 100 47 4700 96 37.60 85% 113 31.96 114.9 1 1 114.9 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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

G O-ring, Trans Exchanger Asm. 021204-B0502-11

G Nut, Exchanger Asm 021204-B0502-12

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

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

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

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

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

$0.00

$0.10

$0.12

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.

G Retainer, Line to Line 021204-B0502-13

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$2.78 $2.35 $5.94 $0.02 $0.35 $0.24 $0.01 $0.62

$6.56

2

Notes: 

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

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! -

G Closeout Plate, Exchanger Core, Stamped 021204-B0502-01

G Inner Plate, Exchanger Core, Stamped 021204-B0502-02

G Upper Plate, Exchanger Core, Stamped 021204-B0502-03

G Fin Baffles, Exchanger Core, Roll Formed 021204-B0502-04

G Exchanger Core Asm, Trans Cooler 021204-B0502-05

G Fitting, Exchanger Asm 021204-B0502-06

021204-B0502-06A

G Exchanger Base Plate 021204-B0502-07

G Exchanger Asm, Trans Cooler 021204-B0502-08

2118 1.70 0.50

2000 1.80 0.50

2000 1.80 0.50

4500 0.80 0.50

144 24.93 1.50

327 11.00 1.00

113 32.00 1.50

5143 0.70 0.50

189 19.00 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: 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.

021204-B0502-08A

021204-B0502-08B

G Trans Exchanger,Radiator Mount 021204-B0502-08C

G Retainer, Line to Line 021204-B0502-09

G Trans Cooler System 021204-B0502-10

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

129 28.00 1.50

277 13.00 0.25

212 17.00 1.00

2769 1.30 1.00

125 28.73 2.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

G O-ring, Trans Exchanger Asm. 021204-B0502-11

G Nut, Exchanger Asm 021204-B0502-12

#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.

G Retainer, Line to Line 021204-B0502-13

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 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#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: G Trans Cooler System Part Number: 021204-B0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 1.1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

Costs Broken Out In

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

Parallel HEV Technology 

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 G Trans Exchanger Line Separator 021204-B0502-14 1 Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 2769 1 1 1 0.017 $1.74 $41.48 $16.39 $16.39 $0.03 $0.01 $0.01 $0.05 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.06 $0.06 $0.03

3 G Trans Exchanger Line Clamp 021204-B0502-15 1 Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS Inject. Mold, SS 2769 1 1 1 0.030 $1.74 $41.48 $16.39 $16.39 $0.05 $0.01 $0.01 $0.07 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.08 $0.08 $0.05

4 G Supply Line, Exchanger, 021204-B0502-16 1 Bend/Flare ends T2/T3 Comp./Ext. Mold, SSLC LC-Steel-1215, Tubing Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC 127 2 4 1 0.5564 $0.62 $42.73 $50.00 $200.00 $0.34 $0.67 $1.57 $2.59 0.30% 6.00% 4.00% 0.00% 10.30% $0.27 $2.85 $2.85 $0.34

5

G Supply Tube Hose

021204-B0502-17 1 Extrude T2/T3 Comp./Ext. Mold, SSLC Thermoset-SBR Extruding/Drawing Operator Extrusion Molding, NR, SS 667 1 1 1 0.089 $1.32 $56.05 $35.94 $35.94 $0.12 $0.08 $0.05 $0.26 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.28 $0.28 $0.12

6

G Return Tube Hose

021204-B0502-18 1 Extrude T2/T3 Comp./Ext. Mold, SSLC Thermoset-SBR Extruding/Drawing Operator Extrusion Molding, NR, SS 444 1 1 1 0.1349 $1.32 $56.05 $35.94 $35.94 $0.18 $0.13 $0.08 $0.39 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.42 $0.42 $0.18

6 G Supply Tube, Quick Connect Female 021204-B0502-19 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 138 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.28 $0.11 $0.39 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.43 $0.43 $0.00

7 G Return Tube, Quick Connect Female 021204-B0502-20 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 138 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.28 $0.11 $0.39 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.43 $0.43 $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#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: G Trans Cooler System Part Number: 021204-B0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Parallel HEV Technology 

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

5 G Tube Retainer, Quick Disconnect 021204-B0502-21 1 Mold T2/T3 Inject. Mold, SSLC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 6000 1 1 1 0.001 $1.54 $41.48 $16.39 $16.39 $0.00 $0.01 $0.00 $0.01 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.01 $0.01 $0.00

6 G Tube Guide, Quick Disconnect 021204-B0502-22 1 Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 4200 1 1 1 0.004 $1.74 $41.48 $16.39 $16.39 $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

7 G Tube Retainer, Quick Disconnect 021204-B0502-23 1 Mold T2/T3 Inject. Mold, SSLC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 6000 1 1 1 0.001 $1.54 $41.48 $16.39 $16.39 $0.00 $0.01 $0.00 $0.01 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.01 $0.01 $0.00

8 G Tube Guide, Quick Disconnect 021204-B0502-24 1 Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 4200 1 1 1 0.004 $1.74 $41.48 $16.39 $16.39 $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

9 G Crimped Body, Quick Disconnect Asm 021204-B0502-25 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LC 277 0.25 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.03 $0.04 $0.07 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.08 $0.08 $0.00

8 021204-B0502-25A 1 Machine T2/T3 CNC Turning, SSLC Aluminum-4032, Bar CNC Operator CNC Turning, SS, BF, DA 122 1 2 1 0.210 $1.44 $36.98 $20.48 $40.96 $0.30 $0.30 $0.34 $0.94 0.30% 6.00% 4.00% 0.00% 10.30% $0.10 $1.04 $1.04 $0.30

10 G Crimped Body, Quick Disconnect Asm 021204-B0502-26 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LC 277 0.25 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.03 $0.04 $0.07 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.08 $0.08 $0.00

10 021204-B0502-26A 1 Machine T2/T3 CNC Turning, SSLC Aluminum-4032, Bar CNC Operator CNC Turning, SS, BF, DA 122 1 2 1 0.210 $1.44 $36.98 $20.48 $40.96 $0.30 $0.30 $0.34 $0.94 0.30% 6.00% 4.00% 0.00% 10.30% $0.10 $1.04 $1.04 $0.30

11 G Supply Tube Asm, Exchanger 021204-B0502-27 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 277 1 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.14 $0.11 $0.25 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.27 $0.27 $0.00

12 G Return Tube Asm, Exchanger 021204-B0502-28 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 138 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.28 $0.11 $0.39 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.43 $0.43 $0.00

13 G Trans Exchanger Return Line Asm 021204-B0502-29 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 277 1 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.14 $0.11 $0.25 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.27 $0.27 $0.00

14 G Trans Exchanger Supply Line Asm 021204-B0502-30 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 185 1 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.21 $0.16 $0.37 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.41 $0.41 $0.00

14

G Trans Exchanger Line Asm

021204-B0502-31 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 148 1 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.26 $0.20 $0.46 0.30% 6.00% 4.00% 0.00% 10.30% $0.05 $0.51 $0.51 $0.00

15 G Trans Exchanger Line Asm, FEM 021204-B0502-32 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 171 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.22 $0.09 $0.31 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.34 $0.34 $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

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

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#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: G Trans Cooler System Part Number: 021204-B0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Parallel HEV Technology 

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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

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

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

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

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

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

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

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

2 G O-ring, Quick Disconnect Inner Seal 021204-B0502-33 1 S $0.00 $0.05 $0.00 $0.05 $0.05

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub2 G O-ring, Quick Disconnect Inner Seal Assembly. 021204-B0502-33 1 S $0.00 $0.05 $0.00 $0.05 $0.05

3 G Supply Tube Ferrule 021204-B0502-34 2 S $0.00 $0.12 $0.00 $0.24 $0.24

4 Tube Nut Exchanger Supply 021204-B0502-35 1 S $0.00 $0.25 $0.00 $0.25 $0.25

5 G O-ring, Quick Disconnect Inner Tube 021204-B0502-36 1 S $0.00 $0.05 $0.00 $0.05 $0.05

4 G Return Tube Ferrule 021204-B0502-37 2 S $0.00 $0.12 $0.00 $0.24 $0.24

7 Tube Nut Exchanger Supply 021204-B0502-39 1 S $0.00 $0.25 $0.00 $0.25 $0.25

8 G Label, Trans Return Line 021204-B0502-40 1 S $0.00 $0.10 $0.00 $0.10 $0.10

9 G O-ring, Exchanger Line Asm 021204-B0502-41 1 S $0.00 $0.045 $0.00 $0.05 $0.05

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

Assembly.

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

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

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

Mark-up Calculations.

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

Supplier for Subassembly.

Material

$2.56

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

Mark-up $10.31

T1 or OEM Total Manufacturing Cost: $2.56 $3.43 $3.47 $9.46 $0.02 $0.49 $0.33 $0.00 $0.85 $10.31

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 $0.67 $0.62 $0.26 $1.60

Base Cost Impact to Vehicle: $2.56 $3.43 $3.47 $9.46 $0.08 $1.16 $0.95 $0.26 $2.45 $11.91 $0 $0

Packaging Cost: $0.00

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: 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#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: G Trans Cooler System Part Number: 021204-B0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Parallel HEV Technology 

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

Net Cost Impact to Vehicle: $11.91

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:

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for Additional Information

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnable Last 5 Years

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

S. 020909)

Investment $20K for tool Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

Packaging Cost Total: $0.000

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

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

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

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

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.1 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

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)

G Trans Exchanger Line Separator 021204-B0502-14

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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 $0.01 $0.05 $0.00 $0.00 $0.00 $0.00 $0.01 55-150 ton , 10 cavity mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1.3 1 10 13 1.0 1.0

G Trans Exchanger Line Clamp 021204-B0502-15

G Supply Line, Exchanger, 021204-B0502-16

G Supply Tube Hose

021204-B0502-17

G Return Tube Hose

021204-B0502-18

G Supply Tube, Quick Connect Female 021204-B0502-19

G Return Tube, Quick Connect Female 021204-B0502-20

$0.01 $0.01 $0.07 $0.00 $0.00 $0.00 $0.00 $0.01 55-150 ton , 10 cavity mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1.3 1 10 13 1.0 1.0

$0.67 $1.57 $2.59 $0.01 $0.16 $0.10 $0.00 $0.27 Tube form and flare, Low complexity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 113 20 1 113 1.0 4.0

$0.08 $0.05 $0.26 $0.00 $0.02 $0.01 $0.00 $0.03 Extrude, autoclave on mandrel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 5.4 1 1 5.4 1.0 1.0

$0.13 $0.08 $0.39 $0.00 $0.02 $0.02 $0.00 $0.04 Extrude, autoclave on mandrel 5 2 10 100 47 4700 96 37.60 85% 113 31.96 8.1 1 1 8.1 1.0 1.0

$0.28 $0.11 $0.39 $0.00 $0.02 $0.02 $0.00 $0.04 Slip on outer washer. Place retainer guide and o-ring in body.Bend/crimp lip down to secure. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 26 4 1 26 1.0 1.0

$0.28 $0.11 $0.39 $0.00 $0.02 $0.02 $0.00 $0.04 Slip on outer washer. Place retainer guide and o-ring in body.Bend/crimp lip down to secure. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 26 4 1 26 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.

G Tube Retainer, Quick Disconnect 021204-B0502-21

G Tube Guide, Quick Disconnect 021204-B0502-22

G Tube Retainer, Quick Disconnect 021204-B0502-23

G Tube Guide, Quick Disconnect 021204-B0502-24

G Crimped Body, Quick Disconnect Asm 021204-B0502-25

021204-B0502-25A

G Crimped Body, Quick Disconnect Asm 021204-B0502-26

021204-B0502-26A

G Supply Tube Asm, Exchanger 021204-B0502-27

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

$0.01 $0.00 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 ton , 14 cavity mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.60 1 14 8.4 1.0 1.0

$0.01 $0.00 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 ton , 14 cavity mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1 1 14 12 1.0 1.0

$0.01 $0.00 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 ton , 14 cavity mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.60 1 14 8.4 1.0 1.0

$0.01 $0.00 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 ton , 14 cavity mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1 1 14 12 1.0 1.0

$0.03 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00 $0.01

Batch Wash

5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0

$0.30 $0.34 $0.94 $0.00 $0.06 $0.04 $0.00 $0.10 CNC Turning 2 Axis SL-10 1.75 5 2 10 100 47 4700 96 37.60 85% 113 31.96 59 14 1 59 1.0 2.0

$0.03 $0.04 $0.07 $0.00 $0.00 $0.00 $0.00 $0.01

Batch Wash

5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0

$0.30 $0.34 $0.94 $0.00 $0.06 $0.04 $0.00 $0.10 CNC Turning 2 Axis SL-10 1.75 5 2 10 100 47 4700 96 37.60 85% 113 31.96 59 14 1 59 1.0 2.0

$0.14 $0.11 $0.25 $0.00 $0.01 $0.01 $0.00 $0.03 Attach quick connect to supply hose - crimp ferrules 5 2 10 100 47 4700 96 37.60 85% 113 31.96 26 4 1 26 1.0 2.0

G Return Tube Asm, Exchanger 021204-B0502-28

G Trans Exchanger Return Line Asm 021204-B0502-29

G Trans Exchanger Supply Line Asm 021204-B0502-30

G Trans Exchanger Line Asm

021204-B0502-31

G Trans Exchanger Line Asm, FEM 021204-B0502-32

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

$0.28 $0.11 $0.39 $0.00 $0.02 $0.02 $0.00 $0.04 Attach quick connect to return hose - crimp ferrules 5 2 10 100 47 4700 96 37.60 85% 113 31.96 26 4 1 26 1.0 1.0

$0.14 $0.11 $0.25 $0.00 $0.01 $0.01 $0.00 $0.03 Slip on outer washer. Place retainer guide and o-ring in body.Bend/crimp lip down to secure. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 26 4 1 26 1.0 2.0

$0.21 $0.16 $0.37 $0.00 $0.02 $0.01 $0.00 $0.04 Slip on outer washer. Place retainer guide and o-ring in body.Bend/crimp lip down to secure. Apply label 5 2 10 100 47 4700 96 37.60 85% 113 31.96 39 4 1 39 1.0 2.0

$0.26 $0.20 $0.46 $0.00 $0.03 $0.02 $0.00 $0.05 Align Trans Exchanger return & supply tube. Place in line seperators and press in place 5 2 10 100 47 4700 96 37.60 85% 113 31.96 48.5 4 1 48.5 1.0 2.0

$0.22 $0.09 $0.31 $0.00 $0.02 $0.01 $0.00 $0.03 Slip on two o-rings 5 2 10 100 47 4700 96 37.60 85% 113 31.96 21 4 1 21 1.0 1.0

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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)

G O-ring, Quick Disconnect Inner Seal 021204-B0502-33

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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

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

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

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

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

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

$0.00

G O-ring, Quick Disconnect Inner Seal 021204-B0502-33 $0.05

G Supply Tube Ferrule 021204-B0502-34

Tube Nut Exchanger Supply 021204-B0502-35

G O-ring, Quick Disconnect Inner Tube 021204-B0502-36

G Return Tube Ferrule 021204-B0502-37

Tube Nut Exchanger Supply 021204-B0502-39

G Label, Trans Return Line 021204-B0502-40

G O-ring, Exchanger Line Asm 021204-B0502-41

$0.05

$0.24

$0.25

$0.05

$0.24

$0.25

$0.10

$0.05

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$3.43 $3.47 $9.46 $0.02 $0.49 $0.33 $0.00 $0.85

$10.31

2

Notes: 

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

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)

G Trans Exchanger Line Separator 021204-B0502-14

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

2769 1.30 1.00

G Trans Exchanger Line Clamp 021204-B0502-15

G Supply Line, Exchanger, 021204-B0502-16

G Supply Tube Hose

021204-B0502-17

G Return Tube Hose

021204-B0502-18

G Supply Tube, Quick Connect Female 021204-B0502-19

G Return Tube, Quick Connect Female 021204-B0502-20

2769 1.30 1.00

127 28.25 2.00

667 5.40 1.00

444 8.10 1.00

138 26.00 1.00

138 26.00 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: 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.

G Tube Retainer, Quick Disconnect 021204-B0502-21

G Tube Guide, Quick Disconnect 021204-B0502-22

G Tube Retainer, Quick Disconnect 021204-B0502-23

G Tube Guide, Quick Disconnect 021204-B0502-24

G Crimped Body, Quick Disconnect Asm 021204-B0502-25

021204-B0502-25A

G Crimped Body, Quick Disconnect Asm 021204-B0502-26

021204-B0502-26A

G Supply Tube Asm, Exchanger 021204-B0502-27

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

6000 0.60 1.00

4200 0.86 1.00

6000 0.60 1.00

4200 0.86 1.00

277 13.00 0.25

122 29.50 1.00

277 13.00 0.25

122 29.50 1.00

277 13.00 1.00

G Return Tube Asm, Exchanger 021204-B0502-28

G Trans Exchanger Return Line Asm 021204-B0502-29

G Trans Exchanger Supply Line Asm 021204-B0502-30

G Trans Exchanger Line Asm

021204-B0502-31

G Trans Exchanger Line Asm, FEM 021204-B0502-32

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

138 26.00 1.00

277 13.00 1.00

185 19.50 1.00

148 24.25 1.00

171 21.00 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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)

G O-ring, Quick Disconnect Inner Seal 021204-B0502-33

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! -

G O-ring, Quick Disconnect Inner Seal 021204-B0502-33

G Supply Tube Ferrule 021204-B0502-34

Tube Nut Exchanger Supply 021204-B0502-35

G O-ring, Quick Disconnect Inner Tube 021204-B0502-36

G Return Tube Ferrule 021204-B0502-37

Tube Nut Exchanger Supply 021204-B0502-39

G Label, Trans Return Line 021204-B0502-40

G O-ring, Exchanger Line Asm 021204-B0502-41

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 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#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: G Trans Cooler System Part Number: 021204-B0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 1.1 0.000 #N/A #N/A #N/A #N/A #N/A #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

Parallel HEV Technology 

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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 G Trans Supply Line G Trans Supply Line 021204-B0502-42A 021204-B0502-42A 1 Bend/Flare ends Bend/Flare ends T2/T3 Comp./Ext. Mold, SSLC T2/T3 Comp./Ext. Mold, SSLC LC-Steel-1215, Tubing LC-Steel-1215, Tubing Cut/Punch/Forming Operator Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC Hydro/CNC Form, SMS, LMC 131 1 2 1 0.3022 $0.62 $42.73 $50.00 $100.00 $100.00 $0.19 $0.33 $0.76 $1.28 0.30% 6.00% 4.00% 0.00% 10.30% $0.13 $1.41 $1.41 $0.19

3 021204-B0502-42 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 300 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.06 $0.05 $0.11 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.13 $0.13 $0.00

3 G Trans Return Line 021204-B0502-43A 1 Bend/Flare ends T2/T3 Comp./Ext. Mold, SSLC LC-Steel-1215, Tubing Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC 141 1 2 1 0.4225 $0.62 $42.73 $50.00 $100.00 $0.26 $0.30 $0.71 $1.27 0.30% 6.00% 4.00% 0.00% 10.30% $0.13 $1.40 $1.40 $0.26

4 021204-B0502-43 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 225 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.09 $0.07 $0.15 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.17 $0.17 $0.00

5 G Quick Disconnect Asm, Threaded 021204-B0502-44 2 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 187 1 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.21 $0.16 $0.37 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.41 $0.81 $0.00

6 G Tube Retainer, Quick Disconnect 021204-B0502-45 2 Mold T2/T3 Inject. Mold, SSLC Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 6000 1 1 1 0.001 $1.54 $41.48 $16.39 $16.39 $0.00 $0.01 $0.00 $0.01 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.01 $0.02 $0.00

7 G Tube Guide, Quick Disconnect 021204-B0502-46 2 Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 4200 1 1 1 0.004 $1.74 $41.48 $16.39 $16.39 $0.01 $0.01 $0.00 $0.02 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.02 $0.05 $0.01

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#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: G Trans Cooler System Part Number: 021204-B0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Parallel HEV Technology 

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

8 G Threaded Body, Quick Disconnect Asm 021204-B0502-47 2 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LC 277 0.25 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.03 $0.04 $0.07 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.08 $0.16 $0.00

9 021204-B0502-47A 2 Machine T2/T3 CNC Turning, SSLC Aluminum-4032, Bar CNC Operator CNC Turning, SS, BF, DA 159 1.5 3 1 0.1148 $1.44 $36.98 $20.48 $61.44 $0.17 $0.35 $0.39 $0.90 0.30% 6.00% 4.00% 0.00% 10.30% $0.09 $0.99 $1.99 $0.33

10 G Trans Line Bracket 021204-B0502-48 1 Stamp T2/T3 Stamp/Form, MSMC LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals 5143 0.5 1 1 0.305 $0.48 $42.73 $15.50 $15.50 $0.15 $0.00 $0.00 $0.15 0.50% 6.50% 6.00% 1.00% 14.00% $0.02 $0.18 $0.18 $0.15

11 G Trans Line Clamp for Bracket 021204-B0502-49 1 Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 2400 1 1 1 0.029 $1.74 $41.48 $16.39 $16.39 $0.05 $0.02 $0.01 $0.07 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.08 $0.08 $0.05

12 G Trans Line Clamp 021204-B0502-50 1 Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 2400 1 1 1 0.024 $1.74 $41.48 $16.39 $16.39 $0.04 $0.02 $0.01 $0.07 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.07 $0.07 $0.04

13 G Retainer, Trans to Cooler 021204-B0502-51 2 Mold T2/T3 Inject. Mold, SSLC PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 2769 1 1 1 0.025 $1.46 $41.48 $16.39 $16.39 $0.04 $0.01 $0.01 $0.06 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.06 $0.13 $0.07

14 G Trans Cooler Line Asm, Trans 021204-B0502-52 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 114 1.5 3 1 0.000 $0.00 $38.55 $15.00 $45.00 $0.00 $0.51 $0.40 $0.90 0.30% 6.00% 4.00% 0.00% 10.30% $0.09 $1.00 $1.00 $0.00

15 G Trans Cooler Line Asm 021204-B0502-53 1 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 184 1 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.21 $0.16 $0.37 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.41 $0.41 $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

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 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: G Trans Cooler System Part Number: 021204-B0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Parallel HEV Technology 

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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 G Label, Trans Return Line 021204-B0502-54 1 S $0.00 $0.10 $0.00 $0.10 $0.10

4 G Convolute Cover, Trans Supply Line 021204-B0502-55 1 S $0.00 $0.03 $0.00 $0.03 $0.03

5 G O-ring, Quick Disconnect Inner Seal 021204-B0502-56 2 S $0.00 $0.05 $0.00 $0.10 $0.10

4 G O-ring, Quick Disconnect Mount 021204-B0502-57 2 S $0.00 $0.04 $0.00 $0.08 $0.08

7 H Nut, M6 KEPS 021204-B0502-58 2 S $0.00 $0.05 $0.00 $0.10 $0.10

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

$1.52

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

Mark-up $8.41

T1 or OEM Total Manufacturing Cost: $1.52 $2.78 $3.36 $7.66 $0.02 $0.44 $0.29 $0.00 $0.75 $8.41

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

Supplier for 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 ----- ----- ----- $0.04 $0.55 $0.50 $0.21 $1.30

Base Cost Impact to Vehicle: $1.52 $2.78 $3.36 $7.66 $0.06 $0.98 $0.80 $0.21 $2.06 $9.72 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $9.72

a) Items 1,2, & 3 must a

Reference Packaging Database for Additional Information

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#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT Annual Component Volume: Shipping Method:

Component Description: G Trans Cooler System Part Number: 021204-B0502-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Parallel HEV Technology 

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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 Returnable Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote 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! - - - - 1.1 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

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)

G Trans Supply Line 021204-B0502-42A

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

G Trans Supply Line 021204-B0502-42A $0.33 $0.76 $1.28 $0.00 $0.08 $0.05 $0.00 $0.13 Tube form and flare, Low complexity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 55 12 1 55 1.0 2.0

021204-B0502-42

G Trans Return Line 021204-B0502-43A

021204-B0502-43

G Quick Disconnect Asm, Threaded 021204-B0502-44

G Tube Retainer, Quick Disconnect 021204-B0502-45

G Tube Guide, Quick Disconnect 021204-B0502-46

$0.33 $0.76 $1.28 $0.00 $0.08 $0.05 $0.00 $0.13 Tube form and flare, Low complexity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 55 12 1 55 1.0 2.0

$0.06 $0.05 $0.11 $0.00 $0.01 $0.00 $0.00 $0.01 Slip on sleeve 5 2 10 100 47 4700 96 37.60 85% 113 31.96 12 1 1 12 1.0 1.0

$0.30 $0.71 $1.27 $0.00 $0.08 $0.05 $0.00 $0.13 Tube form and flare, Low complexity 5 2 10 100 47 4700 96 37.60 85% 113 31.96 51 10 1 51 1.0 2.0

$0.09 $0.07 $0.15 $0.00 $0.01 $0.01 $0.00 $0.02 Attach Label 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 1 1 16 1.0 1.0

$0.41 $0.32 $0.73 $0.00 $0.04 $0.03 $0.00 $0.08 Slip on outer washer. Place retainer guide and o-ring in body.Bend/crimp lip down to secure. 5 2 10 100 47 4700 191 18.80 85% 225 15.98 39 4 1 39 1.0 2.0

$0.01 $0.01 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 ton , 14 cavity mold 5 2 10 100 47 4700 191 18.80 85% 225 15.98 0.60 1 14 8.4 1.0 1.0

$0.02 $0.01 $0.04 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 ton , 14 cavity mold 5 2 10 100 47 4700 191 18.80 85% 225 15.98 1 1 14 12 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.

G Threaded Body, Quick Disconnect Asm 021204-B0502-47

021204-B0502-47A

G Trans Line Bracket 021204-B0502-48

G Trans Line Clamp for Bracket 021204-B0502-49

G Trans Line Clamp 021204-B0502-50

G Retainer, Trans to Cooler 021204-B0502-51

G Trans Cooler Line Asm, Trans 021204-B0502-52

G Trans Cooler Line Asm 021204-B0502-53

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

$0.07 $0.08 $0.15 $0.00 $0.01 $0.01 $0.00 $0.02

Batch Wash

5 2 10 100 47 4700 191 18.80 85% 225 15.98 13 1 1 13 1.0 1.0

$0.70 $0.77 $1.80 $0.01 $0.11 $0.07 $0.00 $0.19 CNC Turning 2 Axis SL-10 1.75 5 2 10 100 47 4700 191 18.80 85% 225 15.98 68 13 1 68 1.0 3.0

$0.00 $0.00 $0.15 $0.00 $0.01 $0.01 $0.00 $0.02 0-60 ton progressive die 5 2 10 100 47 4700 96 37.60 85% 113 31.96 0.7 1 1 0.7 1.0 1.0

$0.02 $0.01 $0.07 $0.00 $0.00 $0.00 $0.00 $0.01 55-150 ton , 10 cavity mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1.5 1 10 15 1.0 1.0

$0.02 $0.01 $0.07 $0.00 $0.00 $0.00 $0.00 $0.01 55-150 ton , 10 cavity mold 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1.5 1 10 15 1.0 1.0

$0.03 $0.01 $0.11 $0.00 $0.01 $0.00 $0.00 $0.01 55-150 ton , 8 cavity mold 5 2 10 100 47 4700 191 18.80 85% 225 15.98 1.3 1 8 10 1.0 1.0

$0.51 $0.40 $0.90 $0.00 $0.05 $0.04 $0.00 $0.09 Qiuck connect fittings at trans and to trans cooler lines. Place retainers on lines and snap in place. Attach 

to trans mount bracket and fasten to trans 5 2 10 100 47 4700 96 37.60 85% 113 31.96 94.9 4 1 94.9 1.0 3.0

$0.21 $0.16 $0.37 $0.00 $0.02 $0.01 $0.00 $0.04 Place and align trans supply and return lines with clamps and snap shut. Attach trans line brkt, 5 2 10 100 47 4700 96 37.60 85% 113 31.96 39.1 4 1 39.1 1.0 2.0

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

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)

G Label, Trans Return Line 021204-B0502-54

G Convolute Cover, Trans Supply Line 021204-B0502-55

G O-ring, Quick Disconnect Inner Seal 021204-B0502-56

G O-ring, Quick Disconnect Mount 021204-B0502-57

H Nut, M6 KEPS 021204-B0502-58

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

$0.10

$0.03

$0.10

$0.08

$0.10

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$2.78 $3.36 $7.66 $0.02 $0.44 $0.29 $0.00 $0.75

$8.41

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)

G Trans Supply Line 021204-B0502-42A

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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 Trans Supply Line 021204-B0502-42A 131 27.50 1.00

021204-B0502-42

G Trans Return Line 021204-B0502-43A

021204-B0502-43

G Quick Disconnect Asm, Threaded 021204-B0502-44

G Tube Retainer, Quick Disconnect 021204-B0502-45

G Tube Guide, Quick Disconnect 021204-B0502-46

131 27.50 1.00

300 12.00 0.50

141 25.50 1.00

225 16.00 0.50

187 19.30 1.00

6000 0.60 1.00

4200 0.86 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: 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.

G Threaded Body, Quick Disconnect Asm 021204-B0502-47

021204-B0502-47A

G Trans Line Bracket 021204-B0502-48

G Trans Line Clamp for Bracket 021204-B0502-49

G Trans Line Clamp 021204-B0502-50

G Retainer, Trans to Cooler 021204-B0502-51

G Trans Cooler Line Asm, Trans 021204-B0502-52

G Trans Cooler Line Asm 021204-B0502-53

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

277 13.00 0.25

159 22.67 1.50

5143 0.70 0.50

2400 1.50 1.00

2400 1.50 1.00

2769 1.30 1.00

114 31.63 1.50

184 19.55 1.00

#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)

G Label, Trans Return Line 021204-B0502-54

G Convolute Cover, Trans Supply Line 021204-B0502-55

G O-ring, Quick Disconnect Inner Seal 021204-B0502-56

G O-ring, Quick Disconnect Mount 021204-B0502-57

H Nut, M6 KEPS 021204-B0502-58

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
01 14 G Trans Cooler System QTY $$$

G Trans Cooler System

1 1.33

x G Retainer, Line to Line2 0.06

xA G Trans Exchanger, Radiator Mount1 0.39

x G Nut, Exchanger Asm2 0.14

x A1 G Exchanger Asm, Trans Cooler1 1.35

x G O-ring, Trans Exchanger Asm.2 0.11

x G Exchanger Base Plate1 0.07

x G Fitting, Exchanger Asm1 2.22

x A2 G Exchanger Core Asm, Trans Cooler1 0.86

x G Closeout Plate, Exchanger Core, Stamped1 0.08

x G Fin Baffles, Exchanger Core, Roll Formed 5 0.14

x G Inner Plate, Exchanger Core, Stamped8 0.67

x G Upper Plate, Exchanger Core, Stamped1 0.09

xB G Trans Exchanger Line Asm, FEM1 0.38

x G O-ring, Exchanger Line Asm2 0.10

x B1 G Trans Exchanger Line Asm1 0.57

x G Trans Exchanger Return Line Asm 1 0.45

x Tube Nut Exchanger Supply1 0.29

x G Label, Trans Return Line1 0.11

x B2 G Return Tube Asm, Exchanger1 0.46

x G Return Tube Hose1 0.48

x G Return Tube Ferrule2 0.28

x G Return Tube, Quick Connect Female 1 0.46

x G Crimped Body, Quick Disconnect Asm, Machined1 1.27

x G O-ring, Quick Disconnect Inner Tube1 0.05

x G Tube Guide, Quick Disconnect 1 0.03

x G Tube Retainer, Quick Disconnect1 0.015

x B3 G Trans Exchanger Supply Line Asm 1 0.45

x G Supply Line, Exchanger, 1 3.28

x Tube Nut Exchanger Supply1 0.29

x G Supply Tube Ferrule1 0.14

x B3A G Supply Tube Asm, Exchanger1 0.38

x G Supply Tube Hose1 0.32

x G Supply Tube Ferrule1 0.14

x B3B G Supply Tube, Quick Connect Female 1 0.46

x G Crimped Body, Quick Disconnect Asm, Machined1 1.27

x G O-ring, Quick Disconnect Inner Seal1 0.05

x G Tube Guide, Quick Disconnect 1 0.03

x G Tube Retainer, Quick Disconnect1 0.015

x B3C G Trans Exchanger Line Clamp1 0.10

x B3D G Trans Exchanger Line Separator1 0.07

xC G Trans Cooler Line Asm, Trans 1 1.05

x H Nut, M6 KEPS2 0.11

x C1 G Trans Cooler Line Asm 1 0.46

x G Trans Line Clamp1 0.09
x G Trans Line Clamp for Bracket

1 0.09

x G Trans Line Bracket1 0.20

x G Retainer, Trans to Cooler 2 0.14

x C2 G Quick Disconnect Asm, Threaded2 0.90

x G Threaded Body, Quick Disconnect Asm2 2.45

x G O-ring, Quick Disconnect Inner Seal2 0.11

x G O-ring, Quick Disconnect Mount2 0.09

x G Tube Guide, Quick Disconnect 2 0.06

x G Tube Retainer, Quick Disconnect2 0.03

x C3 G Trans Cooler Line Asm1 0.18

x G Trans Return Line1 1.61

x G Label, Trans Return Line1 0.11

x C4 G Trans Supply Line Asm1 0.14

x G Trans Supply Line1 1.63

x G Convolute Cover, Trans Supply Line1 0.03

83 28.93
Comments

Commodity?

Commodity

7.51

Commodity

Commodity

Commodity

Commodity

Commodity

Commodity

Commodity

Commodity

11.94

x

x
Commodity

Commodity

Commodity

Commodity

9.48 Commodity
Indented Bill of Materials

G Trans Cooler System

Level Symbol Name Number Qty Material Piece Cost Weight

G Trans Exchanger, Radiator G Trans 

Mounted Exchanger, 

Radiator 

Mounted

1 G Exchanger Asm, Trans G Exchanger 1 # 0.4947 lb

Cooler Asm, Trans 

Cooler

2 G Exchanger Asm, Trans G Exchanger 1 Aluminum #

Cooler, Washed Asm, Trans 

Cooler, 

Washed

3 G Exchanger Asm, Trans G Exchanger 1 Aluminum #

Cooler, Brazed Asm, Trans 

Cooler, 

Washed-1

4 G Exchanger Asm, G Exchanger 1 Aluminum #

Assembled Loose Asm, 

Assembled 

Loose

5 G Exchanger Base Plate G Exchanger 1 Aluminum - #

Base Plate 30xx

6 G Exchanger Base Plate, G Exchanger 1 Aluminum - #

Material Base Plate, 30xx

Material

5 G Exchanger Core Asm, G Exchanger 1 Aluminum- Mn #

Trans Cooler Core Asm, - 30xx - Clad

Trans Cooler

6 G Closeout Plate, Exchanger G Closeout 1 Aluminum- Mn #

Core, Stamped Plate, - 30xx - Clad

Exchanger 

Core, Stamped

7 G Closeout Plate, Exchanger G Closeout 1 Aluminum- Mn - 

Core, Material Plate, 30xx - Clad

Exchanger 

Core, Material

Design Profit®

Page 1 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Level Symbol Name Number Qty Material Piece Cost

G Fin Baffles, Exchanger G Fin Baffles, 1 Aluminum- Mn #

Core, Roll Formed Exchanger - 30xx - Clad
Core, Roll 

Formed

7 G Fin Baffles, Exchanger Core, G Fin Baffles, 1 Aluminum- Mn - 

Material Exchanger 30xx - Clad

Core, Material

6 G Inner Plate, Exchanger G Inner Plate, 1 Aluminum- Mn #

Core, Stamped Exchanger - 30xx - Clad

Core, Stamped

7 G Inner Plate, Exchanger Core, G Inner Plate, 1 Aluminum- Mn - 

Material Exchanger 30xx - Clad

Core, Material

6 G Inner Plate, Exchanger G Inner Plate, 1 Aluminum- Mn #

Core, Stamped Exchanger - 30xx - Clad

Core, Stamped

7 G Inner Plate, Exchanger Core, G Inner Plate, 1 Aluminum- Mn - 

Material Exchanger 30xx - Clad

Core, Material

6 G Fin Baffles, Exchanger G Fin Baffles, 1 Aluminum- Mn #

Core, Roll Formed Exchanger - 30xx - Clad

Core, Roll 

Formed

7 G Fin Baffles, Exchanger Core, G Fin Baffles, 1 Aluminum- Mn - 

Material Exchanger 30xx - Clad

Core, Material

6 G Inner Plate, Exchanger G Inner Plate, 1 Aluminum- Mn #

Core, Stamped Exchanger - 30xx - Clad

Core, Stamped

7 G Inner Plate, Exchanger Core, G Inner Plate, 1 Aluminum- Mn - 

Material Exchanger 30xx - Clad

Core, Material

6 G Inner Plate, Exchanger G Inner Plate, 1 Aluminum- Mn #

Core, Stamped Exchanger - 30xx - Clad

Core, Stamped

7 G Inner Plate, Exchanger Core, G Inner Plate, 1 Aluminum- Mn - 

Material Exchanger 30xx - Clad

Core, Material

6 G Fin Baffles, Exchanger G Fin Baffles, Exchanger G Fin Baffles, G Fin Baffles, 1 Aluminum- Mn uminum- Mn #

Core, Roll Formed Exchanger - 30xx - Clad

Core, Roll 

Formed

Design Profit®

Page 2 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Level Symbol Name Number Qty Material Piece Cost

7 G Fin Baffles, Exchanger Core, G Fin Baffles, Aluminum- Mn - 

Material Exchanger 30xx - Clad

Core, Material

6 G Inner Plate, Exchanger G Inner Plate, 1 Aluminum- Mn #

Core, Stamped Exchanger - 30xx - Clad

Core, Stamped

7 G Inner Plate, Exchanger Core, G Inner Plate, 1 Aluminum- Mn - 

Material Exchanger 30xx - Clad

Core, Material

6 G Inner Plate, Exchanger G Inner Plate, 1 Aluminum- Mn #
Core, Stamped Exchanger - 30xx - Clad

Core, Stamped

7 G Inner Plate, Exchanger Core, G Inner Plate, 1 Aluminum- Mn - 

Material Exchanger 30xx - Clad

Core, Material

6 G Fin Baffles, Exchanger G Fin Baffles, 1 Aluminum- Mn #

Core, Roll Formed Exchanger - 30xx - Clad

Core, Roll 

Formed

7 G Fin Baffles, Exchanger Core, G Fin Baffles, 1 Aluminum- Mn - 

Material Exchanger 30xx - Clad

Core, Material

6 G Inner Plate, Exchanger G Inner Plate, 1 Aluminum- Mn #

Core, Stamped Exchanger - 30xx - Clad

Core, Stamped

7 G Inner Plate, Exchanger Core, G Inner Plate, 1 Aluminum- Mn - 

Material Exchanger 30xx - Clad

Core, Material

6 G Inner Plate, Exchanger G Inner Plate, 1 Aluminum- Mn #

Core, Stamped Exchanger - 30xx - Clad

Core, Stamped

7 G Inner Plate, Exchanger Core, G Inner Plate, 1 Aluminum- Mn - 

Material Exchanger 30xx - Clad

Core, Material

6 G Fin Baffles, Exchanger G Fin Baffles, 1 Aluminum- Mn #

Core, Roll Formed Exchanger - 30xx - Clad

Core, Roll 

Formed

7 G Fin Baffles, Exchanger Core, G Fin Baffles, 1 Aluminum- Mn - 

Material Exchanger 30xx - Clad

Core, Material

Design Profit®

Page 3 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Level Symbol Name Number Qty Material Piece Cost

G Upper Plate, Exchanger G Upper Plate, 1 Aluminum- Mn #

Core, Stamped Exchanger - 30xx - Clad

Core, Stamped

7 G Upper Plate, Exchanger G Upper Plate, 1 Aluminum- Mn - 

Core, Material Exchanger 30xx - Clad

Core, Material

5 G Fitting, Exchanger Asm G Fitting, 2 Aluminum - #

Exchanger 30xx

Asm

6 G Fitting, Exchanger Asm, G Fitting, 1 Aluminum - #

Machined Exchanger 30xx

Asm, 

Machined

7 G Fitting, Exchanger Asm, G Fitting, 1 Aluminum - 

Material Exchanger 30xx

Asm, Material

2 G O-ring, Trans Exchanger G O-ring, Trans 2 Commodity #

Asm Exchanger Asm Pricing
1 G Nut, Exchanger Asm G Nut, 2 Commodity # 0.0224 lb

Exchanger Asm Pricing

0 G Trans Exchanger Line G Trans 1 # 1.4682 lb

Asm, FEM Exchanger 

Line Asm, FEM

1 G Trans Exchanger Line Asm G Trans 1 # 1.4678 lb

Exchanger 

Line Asm

2 G Trans Exchanger Return G Trans 1 #

Line Asm Exchanger 

Return Line 

Asm

3 G Return Line Asm, G Return Line 1 #

Exchanger, Formed Asm, 

Exchanger, 

Formed

4 G Return Line, Exchanger, G Return Line, 1 Commodity #

Material Exchanger, Pricing

Material

4 Tube Nut Exchanger Supply Tube Nut 1 Commodity #

Exchanger Pricing

Supply

3 G Return Tube Asm, G Return Tube 1 #

Exchanger Asm, 

Exchanger

Design Profit®

Page 4 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Level Symbol Name Number Qty Material Piece Cost Weight

G Return Tube Hose G Return Tube 1 EPDM - Fiber 

Hose Reinforced

5 G Return Tube Hose, Material G Return Tube 1 EPDM - Fiber #

Hose, Material Reinforced

4 G Return Tube Ferrule G Return Tube 2 Commodity #

Ferrule Pricing

4 G Return Tube, Quick G Return Tube, 1 #

Connect Female Quick Connect 

Female

5 G Crimped Body, Quick G Crimped 1 Aluminum #

Disconnect, Washed Body, Quick 

Disconnect, 

Washed1

6 G Crimped Body, Quick G Crimped 1 Aluminum #

Disconnect Asm, Machined Body, Quick 

Disconnect 

Asm, 

Machined

7 G Crimped Body, Quick G Crimped 1 Aluminum

Disconnect Asm, Material Body, Quick 

Disconnect 

Asm, Material1

5 G O-ring, Quick Disconnect G O-ring, Quick 1 Commodity #

Inner Seal Disconnect Pricing

Inner Seal

5 G Tube Guide, Quick G Tube Guide, 1 Nylon 6/6 #
Disconnect Quick 

Disconnect

6 G Tube Guide, Quick G Tube Guide, 1 Nylon 6/6 #

Disconnect, Material Quick 

Disconnect, 

Material

5 G Tube Retainer, Quick G Tube 1 PA6-GF30 #

Disconnect Retainer, 

Quick 

Disconnect

6 G Tube Retainer, Quick G Tube 1 PA6-GF30 #

Disconnect, Material Retainer, Quick 

Disconnect, 

Material

3 G Label, Trans Return Line G Label, Trans 1 Commodity #

Return Line Pricing

Design Profit®

Page 5 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Level Symbol Name Number Qty Material Piece Cost Weight

G Trans Exchanger Supply G Trans #

Line Asm Exchanger 

Supply Line 

Asm

3 G Supply Line Asm, G Supply Line 1 Commodity #

Exchanger, Formed Asm, Pricing

Exchanger, 

Formed

4 G Supply Line, Exchanger, G Supply Line, 1 Commodity #

Material Exchanger, Pricing

Material

4 Tube Nut Exchanger Supply Tube Nut 1 Commodity #

Exchanger Pricing

Supply

3 G Supply Tube Asm, G Supply Tube 1 #

Exchanger Asm, 

Exchanger

4 G Supply Tube Hose G Supply Tube 1 EPDM - Fiber #

Hose Reinforced

5 G Supply Tube Hose, Material G Supply Tube 1 EPDM - Fiber #

Hose, Material Reinforced

4 G Supply Tube Ferrule G Supply Tube 2 Commodity #

Ferrule Pricing

4 G Supply Tube, Quick G Supply 1 #

Connect Female Tube, Quick 

Connect 

Female

5 G Crimped Body, Quick G Crimped 1 Aluminum #

Disconnect, Washed Body, Quick 

Disconnect, 

Washed1

6 G Crimped Body, Quick G Crimped 1 Aluminum #

Disconnect Asm, Machined Body, Quick 

Disconnect 
Asm, 

Machined

7 G Crimped Body, Quick G Crimped 1 Aluminum

Disconnect Asm, Material Body, Quick 

Disconnect 

Asm, Material1

5 G O-ring, Quick Disconnect G O-ring, Quick 1 Commodity #

Inner Seal Disconnect Pricing

Inner Seal

Design Profit®

Page 6 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Level Symbol Name Number Qty Material Piece Cost

G Tube Guide, Quick G Tube Guide, 1 Nylon 6/6

Disconnect Quick 

Disconnect

6 G Tube Guide, Quick G Tube Guide, 1 Nylon 6/6 #

Disconnect, Material Quick 

Disconnect, 

Material

5 G Tube Retainer, Quick G Tube 1 PA6-GF30 #

Disconnect Retainer, 

Quick 

Disconnect

6 G Tube Retainer, Quick G Tube 1 PA6-GF30 #

Disconnect, Material Retainer, Quick 

Disconnect, 

Material

2 G Trans Exchanger Line G Trans Exchanger Line G Trans G Trans 2 PA66 #

Clamp Exchanger 

Line Clamp

3 G Trans Exchanger Line G Trans 1 PA66 #

Clamp, Material Exchanger Line 

Clamp, Material

2 G Trans Exchanger Line G Trans 1 PA66 #

Separator Exchanger 

Line Separator

3 G Trans Exchanger Line G Trans 1 PA66 #

Separator, Material Exchanger Line 

Separator, 

Material

1 G O-ring, Exchanger Line Asm G O-ring, 2 Commodity # 0.0002 lb

Exchanger Line Pricing

Asm

0 G Trans Cooler Line Asm, G Trans Cooler 1 # 0.9689 lb

Trans Line Asm, 

Trans

1 G Quick Disconnect Asm, G Quick 2 Commodity # 0.0335 lb

Threaded Disconnect Pricing

Asm, Threaded

2 G Quick Disconnect, G Quick 1 #

Threaded Disconnect, 

Threaded
Design Profit®

Page 7 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Level Symbol Name Number Qty Material Piece Cost Weight

G Threaded Body, Quick G Threaded Aluminum #

Disconnect, Washed Body, Quick 

Disconnect, 

Washed

4 G Threaded Body, Quick G Threaded 1 Aluminum #

Disconnect Asm, Machined Body, Quick 

Disconnect 

Asm, 

Machined

5 G Threaded Body, Quick G Threaded 1 Aluminum #

Disconnect Asm, Material Body, Quick 

Disconnect 

Asm, Material

3 G O-ring, Quick Disconnect G O-ring, Quick 1 Commodity #

Inner Seal Disconnect Pricing

Inner Seal

3 G Tube Guide, Quick G Tube Guide, 1 Nylon 6/6 #

Disconnect Quick 

Disconnect

4 G Tube Guide, Quick G Tube Guide, 1 Nylon 6/6 #

Disconnect, Material Quick 

Disconnect, 

Material

3 G Tube Retainer, Quick G Tube Retainer, Quick G Tube 1 PA6-GF30 #

Disconnect Retainer, 

Quick 

Disconnect

4 G Tube Retainer, Quick G Tube 1 PA6-GF30 #

Disconnect, Material Retainer, Quick 

Disconnect, 

Material

2 G O-ring, Quick Disconnect G O-ring, Quick 1 Commodity #

Mount Disconnect Pricing

Mount

1 G Trans Cooler Line Asm G Trans Cooler 1 # 0.8385 lb

Line Asm

2 G Trans Return Line Asm G Trans Return 1 #

Line Asm

3 G Trans Return Line, G Trans Return 1 Commodity #

Forming Line, Forming Prcing

4 G Trans Return Line, Material G Trans Return 1 Commodity #

Line, Material Prcing

Design Profit®

Page 8 of #

Copyright 2010 © Design Profit, Inc.
G Trans Cooler System

Level Symbol Name Number Qty Material Piece Cost Weight

3 G Label, Trans Return Line G Label, Trans Commodity #

Return Line Pricing

2 G Trans Supply Line Asm G Trans 1 #

Supply Line 

Asm

3 G Trans Supply Line, G Trans 1 Commodity #

Forming Supply Line, Pricing

Forming

4 G Trans Supply Line, Material G Trans Supply 1 Commodity #

Line, Material Pricing

3 G Convolute Cover, Trans G Convolute 1 Commodity #

Supply Line Cover, Trans Pricing

Supply Line

2 G Trans Line Clamp G Trans Line 1 PA66 #

Clamp

3 G Trans Line Clamp, Material G Trans Line 1 PA66 #

Clamp, Material

2 G Trans Line Clamp for G Trans Line 1 PA66 #

Bracket Clamp for 

Bracket

3 G Trans Line Clamp for G Trans Line 1 PA66 #

Bracket, Material Clamp for 

Bracket, 

Material

2 G Trans Line Bracket G Trans Line 1 Galvinized #

Bracket Steel - G60

3 G Trans Line Bracket, Material G Trans Line 1 Galvinized Steel #

Bracket, - G60

Material

1 G Retainer, Trans to Cooler G Retainer, 2 PBT GF 7.5 # 0.0183 lb

Line Trans to 

Cooler Line

2 G Retainer, Trans to Cooler G Retainer, 1 PBT GF 7.5 #

Line, Material Trans to Cooler 

Line, Material

1 H Nut, M6 KEPS H Nut, M6 2 Commodity # 0.0134 lb

KEPS Pricing

0 G Retainer, Line to Line G Retainer, 2 PBT GF 7.5 # 0.0228 lb

Line to Line

1 G Retainer, Line to Line, G Retainer, Line 1 PBT GF 7.5 # 0.0228 lb

Material to Line, Material

Design Profit®

Page 9 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Level Symbol Name Number Qty Material Piece Cost Weight

Assembly Totals Report Totals Preassemble

Analyzed Subs: # Piece Cost (Total): #

Unanalyzed Subs:0
Weight (Total): 3.0222 lb

Parts: #

Fasteners: 4

Parts+Unanalyzed:#

Design Profit®

Page # of #

Copyright 2010 © Design Profit, Inc.
Piece Cost Weight (Total)

(Total)

0.5395 lb 0.5395 lb

0.4947 lb # 0.4947 lb

0.4923 lb # 0.4923 lb

0.4923 lb # 0.4923 lb

0.4923 lb # 0.4923 lb

0.0558 lb # 0.0558 lb

0.0558 lb # 0.0558 lb

0.3723 lb # 0.3723 lb

0.0353 lb # 0.0353 lb

# 0.0353 lb # 0.0353 lb

Weight Piece Cost Weight (Total)

(Total)

0.0080 lb # 0.0080 lb
# 0.0080 lb # 0.0080 lb

0.0329 lb # 0.0329 lb

# 0.0329 lb # 0.0329 lb

0.0329 lb # 0.0329 lb

# 0.0329 lb # 0.0329 lb

0.0080 lb # 0.0080 lb

# 0.0080 lb # 0.0080 lb

0.0329 lb # 0.0329 lb

# 0.0329 lb # 0.0329 lb

0.0329 lb # 0.0329 lb

# 0.0329 lb # 0.0329 lb

0.0080 lb # 0.0080 lb

Piece Cost Weight Piece Cost Weight (Total)

(Total)

# 0.0080 lb 0.0080 lb

0.0329 lb # 0.0329 lb

# 0.0329 lb # 0.0329 lb

0.0329 lb # 0.0329 lb
# 0.0329 lb # 0.0329 lb

0.0080 lb # 0.0080 lb

# 0.0080 lb # 0.0080 lb

0.0329 lb # 0.0329 lb

# 0.0329 lb # 0.0329 lb

0.0329 lb # 0.0329 lb

# 0.0329 lb # 0.0329 lb

0.0080 lb # 0.0080 lb

# 0.0080 lb # 0.0080 lb

Weight Piece Cost Weight (Total)

(Total)

0.0343 lb # 0.0343 lb

# 0.0343 lb # 0.0343 lb

0.0321 lb # 0.0642 lb

0.0321 lb # 0.0642 lb

# 0.0321 lb # 0.0642 lb

0.0012 lb # 0.0024 lb
0.0224 lb # 0.0448 lb

1.4682 lb # 1.4682 lb

1.4678 lb # 1.4678 lb

0.6757 lb # 0.6757 lb

0.4813 lb # 0.4813 lb

0.4491 lb # 0.4491 lb

0.0322 lb # 0.0322 lb

0.1942 lb # 0.1942 lb

Weight Piece Cost Weight (Total)

(Total)

0.1349 lb # 0.1349 lb

0.1349 lb # 0.1349 lb

0.0094 lb # 0.0188 lb

0.0405 lb # 0.0405 lb

0.0368 lb # 0.0368 lb

0.0368 lb # 0.0368 lb

# 0.0368 lb # 0.0368 lb

0.0007 lb # 0.0007 lb

0.0023 lb # 0.0023 lb
0.0023 lb # 0.0023 lb

0.0007 lb # 0.0007 lb

0.0007 lb # 0.0007 lb

0.0002 lb # 0.0002 lb

Piece Cost Weight (Total)

(Total)

0.7346 lb 0.7346 lb

0.5861 lb # 0.5861 lb

0.5539 lb # 0.5539 lb

0.0322 lb # 0.0322 lb

0.1485 lb # 0.1485 lb

0.0892 lb # 0.0892 lb

0.0892 lb # 0.0892 lb

0.0094 lb # 0.0188 lb

0.0405 lb # 0.0405 lb

0.0368 lb # 0.0368 lb

0.0368 lb # 0.0368 lb
# 0.0368 lb # 0.0368 lb

0.0007 lb # 0.0007 lb

Weight Piece Cost Weight (Total)

(Total)

0.0023 lb # 0.0023 lb

0.0023 lb # 0.0023 lb

0.0007 lb # 0.0007 lb

0.0007 lb # 0.0007 lb

0.0227 lb # 0.0454 lb

0.0227 lb # 0.0454 lb

0.0121 lb # 0.0121 lb

0.0121 lb # 0.0121 lb

0.0002 lb # 0.0004 lb

0.9689 lb # 0.9689 lb

0.0335 lb # 0.0670 lb

0.0329 lb # 0.0658 lb
Weight Piece Cost Weight (Total)

(Total)

0.0292 lb 0.0584 lb

0.0292 lb # 0.0584 lb

0.0292 lb # 0.0584 lb

0.0007 lb # 0.0014 lb

0.0023 lb # 0.0046 lb

0.0023 lb # 0.0046 lb

0.0007 lb # 0.0014 lb

0.0007 lb # 0.0014 lb

0.0006 lb # 0.0012 lb

0.8385 lb # 0.8385 lb

0.4202 lb # 0.4202 lb

0.4200 lb # 0.4200 lb

0.4200 lb # 0.4200 lb
Weight Piece Cost Weight (Total)

(Total)

0.0002 lb 0.0002 lb

0.3066 lb # 0.3066 lb

0.3000 lb # 0.3000 lb

0.3000 lb # 0.3000 lb

0.0066 lb # 0.0066 lb

0.0181 lb # 0.0181 lb

0.0181 lb # 0.0181 lb

0.0220 lb # 0.0220 lb

0.0220 lb # 0.0220 lb

0.0716 lb # 0.0716 lb

0.0716 lb # 0.0716 lb

0.0183 lb # 0.0366 lb

0.0183 lb # 0.0366 lb

0.0134 lb # 0.0268 lb

0.0228 lb # 0.0456 lb

0.0228 lb # 0.0456 lb

Piece Cost Weight (Total)

(Total)

Preassembled Totals

Analyzed Subs: 0

Unanalyzed Subs: 0
Parts: 0

Fasteners: 0

Parts+Unanalyzed: 0
Assembly Report

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$83.31 Tool G Trans Cooler First Fixture 0.0000 sec

System

- - - Exchanger & Lines Mounted on - -

FEM

$35.51 Subassembly G Trans Cooler G Trans Exchanger, Radiator G Trans 3.0000 sec

System Mounted Exchanger, 

Radiator Mounted

$35.51 Tool G Trans First Fixture 0.0000 sec

Exchanger, 

Radiator Mounted

- - - Cooler Mounts inside RH - -

Radiator Tank

$35.51 Subassembly G Trans G Exchanger Asm, Trans Cooler G Exchanger 10.0000 sec

Exchanger, Asm, Trans 

Radiator Mounted Cooler

$35.51 Tool G Exchanger First Fixture 0.0000 sec

Asm, Trans 

Cooler

$49.29 Subassembly G Exchanger G Exchanger Asm, Trans Cooler, G Exchanger 3.0000 sec

Asm, Trans Washed Asm, Trans 

Cooler Cooler, Washed

$49.29 Tool G Exchanger Washer Med Batch special 0.0000 sec

Asm, Trans nozzels

Cooler, Washed

$46.52 Subassembly G Exchanger G Exchanger Asm, Trans Cooler, G Exchanger 3.0000 sec

Asm, Trans Brazed Asm, Trans 

Cooler, Washed Cooler, Washed-1

$46.52 Tool G Exchanger Furnace/Oven 0.0000 sec

Asm, Trans 

Cooler, Brazed

$42.18 Subassembly G Exchanger G Exchanger Asm, Assembled G Exchanger 3.0000 sec

Asm, Trans Loose Asm, Assembled 

Cooler, Brazed Loose

$42.18 Tool G Exchanger First Fixture 0.0000 sec

Asm, Assembled 

Loose

Design Profit ®

Page 1 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$15.50 P.-P. Part G Exchanger G Exchanger Base Plate G Exchanger 3.0000 sec

Asm, Assembled Base Plate

Loose
$15.50 Tool G Exchanger Stamping Press 0-60 Ton 0.0000 sec

Base Plate

$15.50 Part G Exchanger G Exchanger Base Plate, G Exchanger 0.0000 sec

Base Plate Material Base Plate, 

Material

- - - Blank weight 0.062 lbs - -

- - - Press Size 60 Ton Prog - -

- - - Part Size after stamping (282 L - -

by 2 W by 2 H)mm

$42.18 Subassembly G Exchanger G Exchanger Core Asm, Trans G Exchanger Core 5.0000 sec

Asm, Assembled Cooler Asm, Trans 

Loose Cooler

$42.18 Tool G Exchanger Core First Fixture 0.0000 sec

Asm, Trans 

Cooler

$42.91 Subassembly G Exchanger Core G Closeout Plate, Exchanger G Closeout Plate, 3.0000 sec

Asm, Trans Core, Stamped Exchanger Core, 

Cooler Stamped

$42.91 Tool G Closeout Plate, Stamping Press 200-400 Ton 0.0000 sec

Exchanger Core, 

Stamped

$42.91 Part G Closeout Plate, G Closeout Plate, Exchanger G Closeout Plate, 0.0000 sec

Exchanger Core, Core, Material Exchanger Core, 

Stamped Material

- - - Blank weight 0.038 lbs - -

- - - Press Size 200 Ton Prog - -

- - - Part Size after stamping (282 L - -

by 28 W by 3 H)mm

$42.18 Subassembly G Exchanger Core G Fin Baffles, Exchanger Core, G Fin Baffles, 4.0000 sec

Asm, Trans Roll Formed Exchanger Core, 

Cooler Roll Formed

$42.18 Tool G Fin Baffles, Roll Form Machine 0.0000 sec

Exchanger Core, 

Roll Formed

$42.18 Part G Fin Baffles, G Fin Baffles, Exchanger Core, G Fin Baffles, 0.0000 sec

Exchanger Core, Material Exchanger Core, 

Roll Formed Material

- - - Start with 0.28mm Clad Stock - -

Design Profit ®

Page 2 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$42.18 Material Mod. G Fin Baffles, Roll Form Fin 0.0582 sec

Exchanger Core, 

Roll Formed

$42.91 Subassembly G Exchanger Core G Inner Plate, Exchanger Core, G Inner Plate, 5.0000 sec

Asm, Trans Stamped Exchanger Core, 

Cooler Stamped

$42.91 Tool G Inner Plate, Stamping Press 200-400 Ton 0.0000 sec

Exchanger Core, 

Stamped

$42.91 Part G Inner Plate, G Inner Plate, Exchanger Core, G Inner Plate, 0.0000 sec

Exchanger Core, Material Exchanger Core, 
Stamped Material

- - - Blank weight 0.038 lbs - -

- - - Press Size 300 Ton Prog - -

- - - Part Size after stamping (282 L - -

by 28 W by 3 H)mm

$42.18 Operation G Exchanger Core CDI 1.0000 sec

Asm, Trans 

Cooler

$42.91 Subassembly G Exchanger Core G Inner Plate, Exchanger Core, G Inner Plate, 5.0000 sec

Asm, Trans Stamped Exchanger Core, 

Cooler Stamped

$42.91 Tool G Inner Plate, Stamping Press 200-400 Ton 0.0000 sec

Exchanger Core, 

Stamped

$42.91 Part G Inner Plate, G Inner Plate, Exchanger Core, G Inner Plate, 0.0000 sec

Exchanger Core, Material Exchanger Core, 

Stamped Material

- - - Blank weight 0.038 lbs - -

- - - Press Size 300 Ton Prog - -

- - - Part Size after stamping (282 L - -

by 28 W by 3 H)mm

$42.18 Subassembly G Exchanger Core G Fin Baffles, Exchanger Core, G Fin Baffles, 4.0000 sec

Asm, Trans Roll Formed Exchanger Core, 

Cooler Roll Formed

$42.18 Tool G Fin Baffles, Roll Form Machine 0.0000 sec

Exchanger Core, 

Roll Formed

$42.18 Part G Fin Baffles, G Fin Baffles, Exchanger Core, G Fin Baffles, 0.0000 sec

Exchanger Core, Material Exchanger Core, 

Roll Formed Material

- - - Start with 0.28mm Clad Stock - -

Design Profit ®

Page 3 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$42.18 Material Mod. G Fin Baffles, Roll Form Fin 0.0582 sec

Exchanger Core, 

Roll Formed

$42.18 Operation G Exchanger Core CDI 1.0000 sec

Asm, Trans 

Cooler

$42.91 Subassembly G Exchanger Core G Inner Plate, Exchanger Core, G Inner Plate, 5.0000 sec

Asm, Trans Stamped Exchanger Core, 

Cooler Stamped

$42.91 Tool G Inner Plate, Stamping Press 200-400 Ton 0.0000 sec

Exchanger Core, 

Stamped

$42.91 Part G Inner Plate, G Inner Plate, Exchanger Core, G Inner Plate, 0.0000 sec

Exchanger Core, Material Exchanger Core, 

Stamped Material

- - - Blank weight 0.038 lbs - -

- - - Press Size 300 Ton Prog - -

- - - Part Size after stamping (282 L - -

by 28 W by 3 H)mm
$42.18 Operation G Exchanger Core CDI 1.0000 sec

Asm, Trans 

Cooler

$42.91 Subassembly G Exchanger Core G Inner Plate, Exchanger Core, G Inner Plate, 5.0000 sec

Asm, Trans Stamped Exchanger Core, 

Cooler Stamped

$42.91 Tool G Inner Plate, Stamping Press 200-400 Ton 0.0000 sec

Exchanger Core, 

Stamped

$42.91 Part G Inner Plate, G Inner Plate, Exchanger Core, G Inner Plate, 0.0000 sec

Exchanger Core, Material Exchanger Core, 

Stamped Material

- - - Blank weight 0.038 lbs - -

- - - Press Size 300 Ton Prog - -

- - - Part Size after stamping (282 L - -

by 28 W by 3 H)mm

$42.18 Subassembly G Exchanger Core G Fin Baffles, Exchanger Core, G Fin Baffles, 4.0000 sec

Asm, Trans Roll Formed Exchanger Core, 

Cooler Roll Formed

$42.18 Tool G Fin Baffles, Roll Form Machine 0.0000 sec

Exchanger Core, 

Roll Formed

Design Profit ®

Page 4 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$42.18 Part G Fin Baffles, G Fin Baffles, Exchanger Core, G Fin Baffles, 0.0000 sec

Exchanger Core, Material Exchanger Core, 

Roll Formed Material

- - - Start with 0.28mm Clad Stock - -

$42.18 Material Mod. G Fin Baffles, Roll Form Fin 0.0582 sec

Exchanger Core, 

Roll Formed

$42.18 Operation G Exchanger Core CDI 1.0000 sec

Asm, Trans 

Cooler

$42.91 Subassembly G Exchanger Core G Inner Plate, Exchanger Core, G Inner Plate, 5.0000 sec

Asm, Trans Stamped Exchanger Core, 

Cooler Stamped

$42.91 Tool G Inner Plate, Stamping Press 200-400 Ton 0.0000 sec

Exchanger Core, 

Stamped

$42.91 Part G Inner Plate, G Inner Plate, Exchanger Core, G Inner Plate, 0.0000 sec

Exchanger Core, Material Exchanger Core, 

Stamped Material

- - - Blank weight 0.038 lbs - -

- - - Press Size 300 Ton Prog - -

- - - Part Size after stamping (282 L - -

by 28 W by 3 H)mm

$42.18 Operation G Exchanger Core CDI 1.0000 sec

Asm, Trans 

Cooler

$42.91 Subassembly G Exchanger Core G Inner Plate, Exchanger Core, G Inner Plate, 5.0000 sec
Asm, Trans Stamped Exchanger Core, 

Cooler Stamped

$42.91 Tool G Inner Plate, Stamping Press 200-400 Ton 0.0000 sec

Exchanger Core, 

Stamped

$42.91 Part G Inner Plate, G Inner Plate, Exchanger Core, G Inner Plate, 0.0000 sec

Exchanger Core, Material Exchanger Core, 

Stamped Material

- - - Blank weight 0.038 lbs - -

- - - Press Size 300 Ton Prog - -

- - - Part Size after stamping (282 L - -

by 28 W by 3 H)mm

$42.18 Subassembly G Exchanger Core G Fin Baffles, Exchanger Core, G Fin Baffles, 4.0000 sec

Asm, Trans Roll Formed Exchanger Core, 

Cooler Roll Formed

Design Profit ®

Page 5 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$42.18 Tool G Fin Baffles, Roll Form Machine 0.0000 sec

Exchanger Core, 

Roll Formed

$42.18 Part G Fin Baffles, G Fin Baffles, Exchanger Core, G Fin Baffles, 0.0000 sec

Exchanger Core, Material Exchanger Core, 

Roll Formed Material

- - - Start with 0.28mm Clad Stock - -

$42.18 Material Mod. G Fin Baffles, Roll Form Fin 0.0582 sec

Exchanger Core, 

Roll Formed

$42.18 Operation G Exchanger Core CDI 1.0000 sec

Asm, Trans 

Cooler

$42.91 Subassembly G Exchanger Core G Inner Plate, Exchanger Core, G Inner Plate, 5.0000 sec

Asm, Trans Stamped Exchanger Core, 

Cooler Stamped

$42.91 Tool G Inner Plate, Stamping Press 200-400 Ton 0.0000 sec

Exchanger Core, 

Stamped

$42.91 Part G Inner Plate, G Inner Plate, Exchanger Core, G Inner Plate, 0.0000 sec

Exchanger Core, Material Exchanger Core, 

Stamped Material

- - - Blank weight 0.038 lbs - -

- - - Press Size 300 Ton Prog - -

- - - Part Size after stamping (282 L - -

by 28 W by 3 H)mm

$42.18 Operation G Exchanger Core CDI 1.0000 sec

Asm, Trans 

Cooler

$42.91 Subassembly G Exchanger Core G Inner Plate, Exchanger Core, G Inner Plate, 5.0000 sec

Asm, Trans Stamped Exchanger Core, 

Cooler Stamped

$42.91 Tool G Inner Plate, Stamping Press 200-400 Ton 0.0000 sec

Exchanger Core, 

Stamped
$42.91 Part G Inner Plate, G Inner Plate, Exchanger Core, G Inner Plate, 0.0000 sec

Exchanger Core, Material Exchanger Core, 

Stamped Material

- - - Blank weight 0.038 lbs - -

- - - Press Size 300 Ton Prog - -

- - - Part Size after stamping (282 L - -

by 28 W by 3 H)mm

Design Profit ®

Page 6 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$42.18 Subassembly G Exchanger Core G Fin Baffles, Exchanger Core, G Fin Baffles, 4.0000 sec

Asm, Trans Roll Formed Exchanger Core, 

Cooler Roll Formed

$42.18 Tool G Fin Baffles, Roll Form Machine 0.0000 sec

Exchanger Core, 

Roll Formed

$42.18 Part G Fin Baffles, G Fin Baffles, Exchanger Core, G Fin Baffles, 0.0000 sec

Exchanger Core, Material Exchanger Core, 

Roll Formed Material

- - - Start with 0.28mm Clad Stock - -

$42.18 Material Mod. G Fin Baffles, Roll Form Fin 0.0582 sec

Exchanger Core, 

Roll Formed

$42.91 Subassembly G Exchanger Core G Upper Plate, Exchanger Core, G Upper Plate, 5.0000 sec

Asm, Trans Stamped Exchanger Core, 

Cooler Stamped

$42.91 Tool G Upper Plate, Stamping Press 200-400 Ton 0.0000 sec

Exchanger Core, 

Stamped

$42.91 Part G Upper Plate, G Upper Plate, Exchanger Core, G Upper Plate, 0.0000 sec

Exchanger Core, Material Exchanger Core, 

Stamped Material

- - - Blank weight 0.038 lbs - -

- - - Press Size 300 Ton Prog - -

- - - Part Size after stamping (282 L - -

by 28 W by 3 H)mm

$42.18 Operation G Exchanger Clamp Part 3.0000 sec

Asm, Assembled 

Loose

$37.60 P.-P. Part G Exchanger G Fitting, Exchanger Asm G Fitting, 3.0000 sec

Asm, Assembled Exchanger Asm

Loose

$37.60 Tool G Fitting, Deburing Equipment 0.0000 sec

Exchanger Asm

$20.90 P.-P. Part G Fitting, G Fitting, Exchanger Asm, G Fitting, 3.0000 sec

Exchanger Asm Machined Exchanger Asm, 

Machined

$20.90 Tool G Fitting, CNC Turning 2 Axis SL-10, 1.75" 0.0000 sec

Exchanger Asm, bar

Machined

- - - Includes Bar Feeder - -
Design Profit ®

Page 7 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$20.90 Part G Fitting, G Fitting, Exchanger Asm, G Fitting, 0.0000 sec

Exchanger Asm, Material Exchanger Asm, 

Machined Material

- - - Bar stock weight 0.1232 lbs. - -

- - - Box size of finished part 36Dmm - -

x 18Lmm

- - - Turn OD, Face End, & Bore - -

Minor OD

$20.90 Material Mod. G Fitting, Turn OD 1-30mm 1.0000 sec

Exchanger Asm, 

Machined

$20.90 Operation G Fitting, Reposition Cutting Tool 2.0000 sec

Exchanger Asm, 

Machined

$20.90 Material Mod. G Fitting, Turn End face 1-30mm 2.0000 sec

Exchanger Asm, 

Machined

$20.90 Operation G Fitting, Auto Tool Change 5.0000 sec

Exchanger Asm, 

Machined

$20.90 Material Mod. G Fitting, Bore Hole 1-30mm 1.0000 sec

Exchanger Asm, 

Machined

- - - Turn Major ID, Cut O-ring - -

Contour Face 

$20.90 Operation G Fitting, Auto Tool Change 5.0000 sec

Exchanger Asm, 

Machined

$20.90 Material Mod. G Fitting, Bore Hole 1-30mm 1.0000 sec

Exchanger Asm, 

Machined

$20.90 Operation G Fitting, Auto Tool Change 5.0000 sec

Exchanger Asm, 

Machined

$20.90 Material Mod. G Fitting, Turn Face Contoured 5.0000 sec

Exchanger Asm, 

Machined

- - - Turn ID Threads, Cut ID Chamfer - -

$20.90 Operation G Fitting, Auto Tool Change 5.0000 sec

Exchanger Asm, 

Machined

Design Profit ®

Page 8 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System
Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$20.90 Material Mod. G Fitting, Turn Threads 2.0000 sec

Exchanger Asm, 

Machined

$20.90 Operation G Fitting, Reposition Cutting Tool 2.0000 sec

Exchanger Asm, 

Machined

$20.90 Material Mod. G Fitting, Turn end face 1-30mm 2.0000 sec

Exchanger Asm, 

Machined

- - - Turn OD, Chamfer & Cut Threads - -

$20.90 Operation G Fitting, Reposition Cutting Tool 2.0000 sec

Exchanger Asm, 

Machined

$20.90 Material Mod. G Fitting, Turn OD 1-30mm 1.0000 sec

Exchanger Asm, 

Machined

$20.90 Operation G Fitting, Reposition Cutting Tool 2.0000 sec

Exchanger Asm, 

Machined

$20.90 Material Mod. G Fitting, Turn Threads 2.0000 sec

Exchanger Asm, 

Machined

$20.90 Operation G Fitting, Reposition Cutting Tool 2.0000 sec

Exchanger Asm, 

Machined

$20.90 Material Mod. G Fitting, Turn end face 1-30mm 2.0000 sec

Exchanger Asm, 

Machined

- - - Turn O-ring Land & Groove, - -

Chamfer & Cut Threads

$20.90 Operation G Fitting, Reposition Cutting Tool 2.0000 sec

Exchanger Asm, 

Machined

$20.90 Material Mod. G Fitting, Turn End face 1-30mm 2.0000 sec

Exchanger Asm, 

Machined

$20.90 Operation G Fitting, Auto Tool Change 5.0000 sec

Exchanger Asm, 

Machined

$20.90 Material Mod. G Fitting, Cut Groove sml 2.0000 sec

Exchanger Asm, 

Machined

Design Profit ®

Page 9 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$20.90 Operation G Fitting, Auto Tool Change 5.0000 sec

Exchanger Asm, 

Machined

$20.90 Material Mod. G Fitting, Turn end face 1-30mm 2.0000 sec
Exchanger Asm, 

Machined

- - - Turn Rear Land, Chamfer & Cut - -

Off

$20.90 Operation G Fitting, Auto Tool Change 5.0000 sec

Exchanger Asm, 

Machined

$20.90 Material Mod. G Fitting, Cut Groove sml 2.0000 sec

Exchanger Asm, 

Machined

$20.90 Operation G Fitting, Reposition Cutting Tool 2.0000 sec

Exchanger Asm, 

Machined

$20.90 Material Mod. G Fitting, Turn end face 1-30mm 2.0000 sec

Exchanger Asm, 

Machined

$20.90 Operation G Fitting, Auto Tool Change 5.0000 sec

Exchanger Asm, 

Machined

$20.90 Material Mod. G Fitting, Cut to Length 1.0000 sec

Exchanger Asm, 

Machined

- - - Rechuck, Turn Rear Face & - -

Chamfer

$20.90 Operation G Fitting, Load Part 3.0000 sec

Exchanger Asm, 

Machined

$20.90 Material Mod. G Fitting, Turn End face 1-30mm 2.0000 sec

Exchanger Asm, 

Machined

$20.90 Operation G Fitting, Reposition Cutting Tool 2.0000 sec

Exchanger Asm, 

Machined

$20.90 Material Mod. G Fitting, Chamfer ID 1.0000 sec

Exchanger Asm, 

Machined

$37.60 Operation G Fitting, Load Part 3.0000 sec

Exchanger Asm

Design Profit ®

Page 10 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$37.60 Material Mod. G Fitting, Debur/Tumble 3.0000 sec

Exchanger Asm

$37.60 Operation G Fitting, Unload Part 2.0000 sec

Exchanger Asm

$42.18 Operation G Exchanger Clamp Part 3.0000 sec

Asm, Assembled 

Loose

$46.52 Operation G Exchanger Load Part 3.0000 sec

Asm, Trans 

Cooler, Brazed

$46.52 Material Mod. G Exchanger Oven Braze large part 20.0000 sec 20.0000 sec

Asm, Trans 
Cooler, Brazed

$46.52 Operation G Exchanger Unload Part 2.0000 sec

Asm, Trans 

Cooler, Brazed

$49.29 Operation G Exchanger Load Part 3.0000 sec

Asm, Trans 

Cooler, Washed

$49.29 Operation G Exchanger Wash Part Medium 5.0000 sec

Asm, Trans 

Cooler, Washed

$49.29 Operation G Exchanger Unload Part 2.0000 sec

Asm, Trans 

Cooler, Washed

$35.51 Part G Exchanger G O-ring, Trans Exchanger Asm G O-ring, Trans 6.0000 sec

Asm, Trans Exchanger Asm

Cooler

$35.51 Fastening G Exchanger Push In Place 2.0000 sec

Asm, Trans 

Cooler

$35.51 Part G Trans G Nut, Exchanger Asm G Nut, Exchanger 6.0000 sec

Exchanger, Asm

Radiator Mounted

$35.51 Tool G Trans Power Tool 4.0000 sec

Exchanger, 

Radiator Mounted

$35.51 Fastening G Trans Power Screw 4.0000 sec

Exchanger, 

Radiator Mounted

$35.51 Subassembly G Trans Cooler G Trans Exchanger Line Asm, G Trans 9.0000 sec

System FEM Exchanger Line 

Asm, FEM

Design Profit ®

Page 11 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$35.51 Tool G Trans First Fixture 0.0000 sec

Exchanger Line 

Asm, FEM

$35.51 Subassembly G Trans G Trans Exchanger Line Asm G Trans 3.0000 sec

Exchanger Line Exchanger Line 

Asm, FEM Asm

$35.51 Tool G Trans First Fixture 0.0000 sec

Exchanger Line 

Asm

$35.51 Subassembly G Trans G Trans Exchanger Return Line G Trans 3.0000 sec

Exchanger Line Asm Exchanger Return 

Asm Line Asm

$35.51 Tool G Trans First Fixture 0.0000 sec

Exchanger Return 

Line Asm

$44.85 Subassembly G Trans G Return Line Asm, Exchanger, G Return Line 3.0000 sec

Exchanger Return Formed Asm, Exchanger, 

Line Asm Formed

$44.85 Tool G Return Line Tube Cutter 0.0000 sec

Asm, Exchanger, 
Formed

$44.85 Part G Return Line G Return Line, Exchanger, G Return Line, 0.0000 sec

Asm, Exchanger, Material Exchanger, 

Formed Material

- - - Start with Tube Stock - -

- - - Weight before machining 0.4516 - -

lbs

$44.85 Operation G Return Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Return Line Cut to Length 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Tool G Return Line Tube Bending Equipment 0.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

Design Profit ®

Page 12 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$44.85 Material Mod. G Return Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Return Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Return Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Unclamp Part 1.0000 sec
Asm, Exchanger, 

Formed

$44.85 Operation G Return Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Return Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

Design Profit ®

Page 13 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$44.85 Operation G Return Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Return Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Return Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Return Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed
$44.85 Operation G Return Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

Design Profit ®

Page 14 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$44.85 Material Mod. G Return Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Return Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Return Line Crimp Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Return Line Crimp Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Part G Return Line Tube Nut Exchanger Supply Tube Nut 7.0000 sec

Asm, Exchanger, Exchanger Supply

Formed

$44.85 Fastening G Return Line Push In Place 2.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Return Line Crimp Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Return Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed
Design Profit ®

Page 15 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$35.51 Subassembly G Trans G Return Tube Asm, Exchanger G Return Tube 9.0000 sec

Exchanger Return Asm, Exchanger

Line Asm

$35.51 Tool G Return Tube First Fixture 0.0000 sec

Asm, Exchanger

$61.22 P.-P. Part G Return Tube G Return Tube Hose G Return Tube 4.0000 sec

Asm, Exchanger Hose

$61.22 Tool G Return Tube Extruder 32mm Reinforced Hose 0.0000 sec

Hose

$61.22 Part G Return Tube G Return Tube Hose, Material G Return Tube 0.0000 sec

Hose Hose, Material

- - - Box Size 220mmL x 150mmW x - -

65mmH

$35.51 Part G Return Tube G Return Tube Ferrule G Return Tube 5.0000 sec

Asm, Exchanger Ferrule

$35.51 Fastening G Return Tube Push On 2.0000 sec

Asm, Exchanger

$35.51 Operation G Return Tube CDI 1.0000 sec

Asm, Exchanger

$35.51 Fastening G Return Tube Push On 2.0000 sec

Asm, Exchanger

$35.51 Subassembly G Return Tube G Return Tube, Quick Connect G Return Tube, 3.0000 sec

Asm, Exchanger Female Quick Connect 

Female

$35.51 Tool G Return Tube, Press 0.0000 sec

Quick Connect 

Female

$10.75 P.-P. Part G Return Tube, G Crimped Body, Quick G Crimped Body, 3.0000 sec

Quick Connect Disconnect, Washed Quick Disconnect, 

Female Washed1

$10.75 Tool G Crimped Body, Washer Duo 400 Wash Rinse & 0.0000 sec

Quick Disconnect, DRY

Washed

$20.90 P.-P. Part G Crimped Body, G Crimped Body, Quick G Crimped Body, 3.0000 sec

Quick Disconnect, Disconnect Asm, Machined Quick Disconnect 

Washed Asm, Machined

$20.90 Tool G Crimped Body, CNC Turning 2 Axis SL-10, 1.75" 0.0000 sec

Quick Disconnect bar

Asm, Machined

- - - Includes Bar Feeder - -

Design Profit ®

Page 16 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System
Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$20.90 Part G Crimped Body, G Crimped Body, Quick G Crimped Body, 0.0000 sec

Quick Disconnect Disconnect Asm, Material Quick Disconnect 

Asm, Machined Asm, Material1

- - - Bar stock weight 0.21 lbs. - -

- - - Box size of finished part 26Dmm - -

x 57Lmm

- - - Face & Bore 3 IDs - -

$20.90 Material Mod. G Crimped Body, Turn End face 1-30mm 2.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Crimped Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Crimped Body, Bore Hole 1-30mm 1.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Crimped Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Crimped Body, Bore Hole 1-30mm 1.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Crimped Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Crimped Body, Bore Hole 1-30mm 1.0000 sec

Quick Disconnect 

Asm, Machined

- - - Turn 4 OD Surfaces & 4 Grooves - -

$20.90 Operation G Crimped Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Crimped Body, Turn OD 1-30mm 1.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Crimped Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Crimped Body, Cut Groove sml 2.0000 sec

Quick Disconnect 

Asm, Machined

- - - Cutoff, Manipulate & Chamfer - -

Design Profit ®

Page 17 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$20.90 Operation G Crimped Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Crimped Body, Cut to Length 1.0000 sec

Quick Disconnect 
Asm, Machined

$20.90 Operation G Crimped Body, Load Part 3.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Crimped Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Crimped Body, Chamfer OD sml 1.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Crimped Body, Unload Part 2.0000 sec

Quick Disconnect 

Asm, Machined

$10.75 Operation G Crimped Body, Load Part 3.0000 sec

Quick Disconnect, 

Washed

$10.75 Operation G Crimped Body, Wash Part Medium 5.0000 sec

Quick Disconnect, 

Washed

$10.75 Operation G Crimped Body, Unload Part 2.0000 sec

Quick Disconnect, 

Washed

$35.51 Part G Return Tube, G O-ring, Quick Disconnect Inner G O-ring, Quick 5.0000 sec

Quick Connect Seal Disconnect Inner 

Female Seal

$35.51 Fastening G Return Tube, Set In Place 1.0000 sec

Quick Connect 

Female

$16.39 P.-P. Part G Return Tube, G Tube Guide, Quick Disconnect G Tube Guide, 5.0000 sec

Quick Connect Quick Disconnect

Female

$16.39 Tool G Tube Guide, First Fixture 0.0000 sec

Quick Disconnect

$16.39 Part G Tube Guide, G Tube Guide, Quick Disconnect, G Tube Guide, 0.0000 sec

Quick Disconnect Material Quick Disconnect, 

Material

- - - Raw Material Req 0.004 lbs from - -

Cost Sheet

Design Profit ®

Page 18 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

- - - 14 Cavity Mold - -

- - - Box Size 21mm L x 21mm W x - -

7mm H

$35.51 Fastening G Return Tube, Set In Place 1.0000 sec

Quick Connect 

Female

$16.39 P.-P. Part G Return Tube, G Tube Retainer, Quick G Tube Retainer, 5.0000 sec

Quick Connect Disconnect Quick Disconnect

Female

$16.39 Tool G Tube Retainer, Injection Molding Machine 55-150 0.0000 sec

Quick Disconnect ton

$16.39 Part G Tube Retainer, G Tube Retainer, Quick G Tube Retainer, 0.0000 sec

Quick Disconnect Disconnect, Material Quick Disconnect, 
Material

- - - Raw Material Req 0.001 lbs from - -

Cost Sheet

- - - 14 Cavity Mold - -

- - - Box Size 18mm L x 18mm W x - -

5mm H

$35.51 Fastening G Return Tube, Set In Place 1.0000 sec

Quick Connect 

Female

$35.51 Fastening G Return Tube, Gross Deform 5.0000 sec

Quick Connect 

Female

$35.51 Fastening G Return Tube Push On 2.0000 sec

Asm, Exchanger

$35.51 Tool G Return Tube Crimping Tool 4.0000 sec

Asm, Exchanger

$35.51 Fastening G Return Tube Crimp Connector, Large 4.0000 sec

Asm, Exchanger

$35.51 Fastening G Trans Push On 2.0000 sec

Exchanger Return 

Line Asm

$35.51 Operation G Trans Align Seat Foam to Base 3.0000 sec

Exchanger Return 

Line Asm

$35.51 Tool G Trans Crimping Tool 4.0000 sec

Exchanger Return 

Line Asm

Design Profit ®

Page 19 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$35.51 Fastening G Trans Crimp Connector, Large 4.0000 sec

Exchanger Return 

Line Asm

$35.51 Part G Trans G Label, Trans Return Line G Label, Trans 10.0000 sec 10.0000 sec

Exchanger Return Return Line

Line Asm

$35.51 Fastening G Trans Apply Label 3.0000 sec

Exchanger Return 

Line Asm

$35.51 Subassembly G Trans G Trans Exchanger Supply Line G Trans 7.0000 sec

Exchanger Line Asm Exchanger Supply 

Asm Line Asm

$35.51 Tool G Trans First Fixture 0.0000 sec

Exchanger Supply 

Line Asm

$44.85 Subassembly G Trans G Supply Line Asm, Exchanger, G Supply Line 3.0000 sec

Exchanger Supply Formed Asm, Exchanger, 

Line Asm Formed

$44.85 Tool G Supply Line Tube Cutter 0.0000 sec

Asm, Exchanger, 

Formed
$44.85 Part G Supply Line G Supply Line, Exchanger, G Supply Line, 0.0000 sec

Asm, Exchanger, Material Exchanger, 

Formed Material

- - - Start with Tube Stock - -

- - - Weight before machining 0.5564 - -

lbs

$44.85 Operation G Supply Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Supply Line Cut to Length 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Tool G Supply Line Tube Bending Equipment 0.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

Design Profit ®

Page 20 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$44.85 Material Mod. G Supply Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Supply Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Supply Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Unclamp Part 1.0000 sec

Asm, Exchanger, 
Formed

$44.85 Operation G Supply Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Supply Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

Design Profit ®

Page 21 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$44.85 Operation G Supply Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Supply Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Supply Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Supply Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line CDI 1.0000 sec
Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

Design Profit ®

Page 22 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$44.85 Material Mod. G Supply Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Supply Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Supply Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Supply Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed
Design Profit ®

Page 23 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$44.85 Operation G Supply Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Supply Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Supply Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Supply Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

Design Profit ®

Page 24 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System
Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$44.85 Material Mod. G Supply Line Bend Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Supply Line Crimp Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Supply Line Crimp Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Part G Supply Line Tube Nut Exchanger Supply Tube Nut 7.0000 sec

Asm, Exchanger, Exchanger Supply

Formed

$44.85 Fastening G Supply Line Push In Place 2.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line CDI 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Clamp Part 3.0000 sec

Asm, Exchanger, 

Formed

$44.85 Material Mod. G Supply Line Crimp Tube 1.0000 sec

Asm, Exchanger, 

Formed

$44.85 Operation G Supply Line Unclamp Part 1.0000 sec

Asm, Exchanger, 

Formed

$35.51 Subassembly G Trans G Supply Tube Asm, Exchanger G Supply Tube 9.0000 sec

Exchanger Supply Asm, Exchanger

Line Asm

$35.51 Tool G Supply Tube First Fixture 0.0000 sec

Asm, Exchanger

$61.22 P.-P. Part G Supply Tube G Supply Tube Hose G Supply Tube 4.0000 sec

Asm, Exchanger Hose

$61.22 Tool G Supply Tube Extruder 32mm Reinforced Hose 0.0000 sec

Hose

$61.22 Part G Supply Tube G Supply Tube Hose, Material G Supply Tube 0.0000 sec

Hose Hose, Material

- - - Box Size 200mmL x 100mmW x - -

100mmH

Design Profit ®

Page 25 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$35.51 Part G Supply Tube G Supply Tube Ferrule G Supply Tube 5.0000 sec

Asm, Exchanger Ferrule

$35.51 Fastening G Supply Tube Push On 2.0000 sec

Asm, Exchanger
$35.51 Operation G Supply Tube CDI 1.0000 sec

Asm, Exchanger

$35.51 Fastening G Supply Tube Push On 2.0000 sec

Asm, Exchanger

$35.51 Subassembly G Supply Tube G Supply Tube, Quick Connect G Supply Tube, 3.0000 sec

Asm, Exchanger Female Quick Connect 

Female

$35.51 Tool G Supply Tube, Press 0.0000 sec

Quick Connect 

Female

$10.75 P.-P. Part G Supply Tube, G Crimped Body, Quick G Crimped Body, 3.0000 sec

Quick Connect Disconnect, Washed Quick Disconnect, 

Female Washed1

$10.75 Tool G Crimped Body, Washer Duo 400 Wash Rinse & 0.0000 sec

Quick Disconnect, DRY

Washed

$20.90 P.-P. Part G Crimped Body, G Crimped Body, Quick G Crimped Body, 3.0000 sec

Quick Disconnect, Disconnect Asm, Machined Quick Disconnect 

Washed Asm, Machined

$20.90 Tool G Crimped Body, CNC Turning 2 Axis SL-10, 1.75" 0.0000 sec

Quick Disconnect bar

Asm, Machined

- - - Includes Bar Feeder - -

$20.90 Part G Crimped Body, G Crimped Body, Quick G Crimped Body, 0.0000 sec

Quick Disconnect Disconnect Asm, Material Quick Disconnect 

Asm, Machined Asm, Material1

- - - Bar stock weight 0.21 lbs. - -

- - - Box size of finished part 26Dmm - -

x 57Lmm

- - - Face & Bore 3 IDs - -

$20.90 Material Mod. G Crimped Body, Turn End face 1-30mm 2.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Crimped Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

Design Profit ®

Page 26 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$20.90 Material Mod. G Crimped Body, Bore Hole 1-30mm 1.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Crimped Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Crimped Body, Bore Hole 1-30mm 1.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Crimped Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined
$20.90 Material Mod. G Crimped Body, Bore Hole 1-30mm 1.0000 sec

Quick Disconnect 

Asm, Machined

- - - Turn 4 OD Surfaces & 4 Grooves - -

$20.90 Operation G Crimped Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Crimped Body, Turn OD 1-30mm 1.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Crimped Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Crimped Body, Cut Groove sml 2.0000 sec

Quick Disconnect 

Asm, Machined

- - - Cutoff, Manipulate & Chamfer - -

$20.90 Operation G Crimped Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Crimped Body, Cut to Length 1.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Crimped Body, Load Part 3.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Crimped Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

Design Profit ®

Page 27 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$20.90 Material Mod. G Crimped Body, Chamfer OD sml 1.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Crimped Body, Unload Part 2.0000 sec

Quick Disconnect 

Asm, Machined

$10.75 Operation G Crimped Body, Load Part 3.0000 sec

Quick Disconnect, 

Washed

$10.75 Operation G Crimped Body, Wash Part Medium 5.0000 sec

Quick Disconnect, 

Washed

$10.75 Operation G Crimped Body, Unload Part 2.0000 sec

Quick Disconnect, 

Washed

$35.51 Part G Supply Tube, G O-ring, Quick Disconnect Inner G O-ring, Quick 5.0000 sec

Quick Connect Seal Disconnect Inner 

Female Seal

$35.51 Fastening G Supply Tube, Set In Place 1.0000 sec

Quick Connect 

Female
$16.39 P.-P. Part G Supply Tube, G Tube Guide, Quick Disconnect G Tube Guide, 5.0000 sec

Quick Connect Quick Disconnect

Female

$16.39 Tool G Tube Guide, First Fixture 0.0000 sec

Quick Disconnect

$16.39 Part G Tube Guide, G Tube Guide, Quick Disconnect, G Tube Guide, 0.0000 sec

Quick Disconnect Material Quick Disconnect, 

Material

- - - Raw Material Req 0.004 lbs from - -

Cost Sheet

- - - 14 Cavity Mold - -

- - - Box Size 21mm L x 21mm W x - -

7mm H

$35.51 Fastening G Supply Tube, Set In Place 1.0000 sec

Quick Connect 

Female

$16.39 P.-P. Part G Supply Tube, G Tube Retainer, Quick G Tube Retainer, 5.0000 sec

Quick Connect Disconnect Quick Disconnect

Female

$16.39 Tool G Tube Retainer, Injection Molding Machine 55-150 0.0000 sec

Quick Disconnect ton

Design Profit ®

Page 28 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$16.39 Part G Tube Retainer, G Tube Retainer, Quick G Tube Retainer, 0.0000 sec

Quick Disconnect Disconnect, Material Quick Disconnect, 

Material

- - - Raw Material Req 0.001 lbs from Raw Material Req 0.001 lbs from - -

Cost Sheet

- - - 14 Cavity Mold - -

- - - Box Size 18mm L x 18mm W x - -

5mm H

$35.51 Fastening G Supply Tube, Set In Place 1.0000 sec

Quick Connect 

Female

$35.51 Fastening G Supply Tube, Gross Deform 5.0000 sec

Quick Connect 

Female

$35.51 Fastening G Supply Tube Push On 2.0000 sec

Asm, Exchanger

$35.51 Tool G Supply Tube Crimping Tool 4.0000 sec

Asm, Exchanger

$35.51 Fastening G Supply Tube Crimp Connector, Large 4.0000 sec

Asm, Exchanger

$35.51 Fastening G Trans Push On 2.0000 sec

Exchanger Supply 

Line Asm

$35.51 Operation G Trans Align Seat Foam to Base 3.0000 sec

Exchanger Supply 

Line Asm

$35.51 Tool G Trans Crimping Tool 4.0000 sec

Exchanger Supply 

Line Asm
$35.51 Fastening G Trans Crimp Connector, Large 4.0000 sec

Exchanger Supply 

Line Asm

$35.51 Operation G Trans Align Seat Foam to Base 3.0000 sec

Exchanger Line 

Asm

$16.39 P.-P. Part G Trans G Trans Exchanger Line Clamp G Trans 9.0000 sec

Exchanger Line Exchanger Line 

Asm Clamp

$16.39 Tool G Trans Injection Molding Machine 55-150 0.0000 sec

Exchanger Line ton

Clamp 

Design Profit ®

Page 29 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$16.39 Part G Trans G Trans Exchanger Line Clamp, G Trans 0.0000 sec

Exchanger Line Material Exchanger Line 

Clamp Clamp, Material

- - - Raw Material Req 0.030 lbs from - -

Cost Sheet

- - - 10 Cavity Mold - -

- - - Box Size 80mm L x 80mm W x - -

30mm H

$35.51 Fastening G Trans Push In Place 2.0000 sec

Exchanger Line 

Asm

$35.51 Operation G Trans 18" Move 2.0000 sec

Exchanger Line 

Asm

$35.51 Fastening G Trans Push In Place 2.0000 sec

Exchanger Line 

Asm

$16.39 P.-P. Part G Trans G Trans Exchanger Line G Trans 9.0000 sec

Exchanger Line Separator Exchanger Line 

Asm Separator

$16.39 Tool G Trans Injection Molding Machine 55-150 0.0000 sec

Exchanger Line ton

Separator

$16.39 Part G Trans G Trans Exchanger Line G Trans 0.0000 sec

Exchanger Line Separator, Material Exchanger Line 

Separator Separator, 

Material

- - - Raw Material Req 0.017 lbs from - -

Cost Sheet

- - - 10 Cavity Mold - -

- - - Box Size 48mm L x 18mm W x - -

16mm H

$35.51 Fastening G Trans Push In Place 2.0000 sec

Exchanger Line 

Asm

$35.51 Part G Trans G O-ring, Exchanger Line Asm G O-ring, 7.0000 sec

Exchanger Line Exchanger Line 
Asm, FEM Asm

$35.51 Fastening G Trans Push In Place 2.0000 sec

Exchanger Line 

Asm, FEM

Design Profit ®

Page 30 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$83.31 Fastening G Trans Cooler Hand Start Screw Loose 2.0000 sec

System

$83.31 Operation G Trans Cooler 18" Move 2.0000 sec

System

$83.31 Multitouch G Trans Cooler G Regrab Exchanger Lines G Regrab 10.0000 sec 10.0000 sec

System Exchanger Lines

$83.31 Fastening G Trans Cooler Press in Xmass Clip 3.0000 sec

System

$83.31 Operation G Trans Cooler 18" Move 2.0000 sec

System

$83.31 Tool G Trans Cooler Hand Tool 3.0000 sec

System

$83.31 Fastening G Trans Cooler Manual Screw 7.0000 sec

System

- - - Trans Lines mounted on Trans - -

$35.51 Subassembly G Trans Cooler G Trans Cooler Line Asm, Trans G Trans Cooler 6.0000 sec

System Line Asm, Trans

$35.51 Tool G Trans Cooler First Fixture 0.0000 sec

Line Asm, Trans

- - - Quick Connect Fittings at Trans - -

$35.51 Subassembly G Trans Cooler G Quick Disconnect Asm, G Quick 3.0000 sec

Line Asm, Trans Threaded Disconnect Asm, 

Threaded

$35.51 Tool G Quick First Fixture 0.0000 sec

Disconnect Asm, 

Threaded

$35.51 Subassembly G Quick G Quick Disconnect, Threaded G Quick 3.0000 sec

Disconnect Asm, Disconnect, 

Threaded Threaded

$35.51 Tool G Quick Press 0.0000 sec

Disconnect, 

Threaded

$10.75 P.-P. Part G Quick G Threaded Body, Quick G Threaded Body, 3.0000 sec

Disconnect, Disconnect, Washed Quick Disconnect, 

Threaded Washed

$10.75 Tool G Threaded Body, Washer Duo 400 Wash Rinse & 0.0000 sec

Quick Disconnect, DRY

Washed

$20.90 P.-P. Part G Threaded Body, G Threaded Body, Quick G Threaded Body, 3.0000 sec

Quick Disconnect, Disconnect Asm, Machined Quick Disconnect 

Washed Asm, Machined

Design Profit ®
Page 31 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$20.90 Tool G Threaded Body, CNC Turning 2 Axis SL-10, 1.75" 0.0000 sec

Quick Disconnect bar

Asm, Machined

- - - Includes Bar Feeder - -

$20.90 Part G Threaded Body, G Threaded Body, Quick G Threaded Body, 0.0000 sec

Quick Disconnect Disconnect Asm, Material Quick Disconnect 

Asm, Machined Asm, Material

- - - Hex Bar stock weight 0.1148 lbs. - -

- - - Box size of finished part 26Dmm - -

x 32Lmm

- - - Face & Bore 3 IDs - -

$20.90 Material Mod. G Threaded Body, Turn End face 1-30mm 2.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Threaded Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Threaded Body, Bore Hole 1-30mm 1.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Threaded Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Threaded Body, Bore Hole 1-30mm 1.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Threaded Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Threaded Body, Bore Hole 1-30mm 1.0000 sec

Quick Disconnect 

Asm, Machined

- - - Turn 2 OD Surfaces & 1 Groove - -

$20.90 Operation G Threaded Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Threaded Body, Turn OD 1-30mm 1.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Threaded Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

Design Profit ®

Page 32 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$20.90 Material Mod. G Threaded Body, Cut Groove sml 2.0000 sec
Quick Disconnect 

Asm, Machined

- - - Turn Thread ODs & Threads - -

$20.90 Operation G Threaded Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Threaded Body, Turn OD 1-30mm 1.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Threaded Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Threaded Body, Turn Threads 2.0000 sec

Quick Disconnect 

Asm, Machined

- - - Cutoff, Manipulate & Chamfer - -

$20.90 Operation G Threaded Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Threaded Body, Cut to Length 1.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Threaded Body, Load Part 3.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Threaded Body, Auto Tool Change 5.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Threaded Body, Chamfer OD sml 1.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Threaded Body, Reposition Cutting Tool 2.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Material Mod. G Threaded Body, Chamfer ID 1.0000 sec

Quick Disconnect 

Asm, Machined

$20.90 Operation G Threaded Body, Unload Part 2.0000 sec

Quick Disconnect 

Asm, Machined

Design Profit ®

Page 33 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$10.75 Operation G Threaded Body, Load Part 3.0000 sec

Quick Disconnect, 

Washed

$10.75 Operation G Threaded Body, Wash Part Medium 5.0000 sec

Quick Disconnect, 

Washed

$10.75 Operation G Threaded Body, Unload Part 2.0000 sec

Quick Disconnect, 

Washed

$35.51 Part G Quick G O-ring, Quick Disconnect Inner G O-ring, Quick 5.0000 sec
Disconnect, Seal Disconnect Inner 

Threaded Seal

$35.51 Fastening G Quick Set In Place 1.0000 sec

Disconnect, 

Threaded

$16.39 P.-P. Part G Quick G Tube Guide, Quick Disconnect G Tube Guide, 5.0000 sec

Disconnect, Quick Disconnect

Threaded

$16.39 Tool G Tube Guide, First Fixture 0.0000 sec

Quick Disconnect

$16.39 Part G Tube Guide, G Tube Guide, Quick Disconnect, G Tube Guide, 0.0000 sec

Quick Disconnect Material Quick Disconnect, 

Material

- - - Raw Material Req 0.004 lbs from - -

Cost Sheet

- - - 14 Cavity Mold - -

- - - Box Size 21mm L x 21mm W x - -

7mm H

$35.51 Fastening G Quick Set In Place 1.0000 sec

Disconnect, 

Threaded

$16.39 P.-P. Part G Quick G Tube Retainer, Quick G Tube Retainer, 5.0000 sec

Disconnect, Disconnect Quick Disconnect

Threaded

$16.39 Tool G Tube Retainer, Injection Molding Machine 55-150 0.0000 sec

Quick Disconnect ton

$16.39 Part G Tube Retainer, G Tube Retainer, Quick G Tube Retainer, 0.0000 sec

Quick Disconnect Disconnect, Material Quick Disconnect, 

Material

- - - Raw Material Req 0.001 lbs from - -

Cost Sheet

- - - 14 Cavity Mold - -

Design Profit ®

Page 34 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

- - - Box Size 18mm L x 18mm W x - -

5mm H

$35.51 Fastening G Quick Set In Place 1.0000 sec

Disconnect, 

Threaded

$35.51 Fastening G Quick Gross Deform 5.0000 sec

Disconnect, 

Threaded

$35.51 Part G Quick G O-ring, Quick Disconnect G O-ring, Quick 6.0000 sec

Disconnect Asm, Mount Disconnect Mount

Threaded

$35.51 Fastening G Quick Push In Place 2.0000 sec

Disconnect Asm, 

Threaded

$35.51 Tool G Trans Cooler Power Tool 4.0000 sec

Line Asm, Trans

$35.51 Fastening G Trans Cooler Power Screw 4.0000 sec

Line Asm, Trans
$35.51 Subassembly G Trans Cooler G Trans Cooler Line Asm G Trans Cooler 4.0000 sec

Line Asm, Trans Line Asm

$35.51 Tool G Trans Cooler First Fixture 0.0000 sec

Line Asm

$35.51 Subassembly G Trans Cooler G Trans Return Line Asm G Trans Return 3.0000 sec

Line Asm Line Asm

$35.51 Tool G Trans Return First Fixture 0.0000 sec

Line Asm

$44.85 Subassembly G Trans Return G Trans Return Line, Forming G Trans Return 3.0000 sec

Line Asm Line, Forming

$44.85 Tool G Trans Return Tube Cutter 0.0000 sec

Line, Forming

$44.85 Part G Trans Return G Trans Return Line, Material G Trans Return 0.0000 sec

Line, Forming Line, Material

- - - Start with Tube Stock - -

- - - Weight before machining 0.4225 - -

lbs

$44.85 Operation G Trans Return Clamp Part 3.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Return Cut to Length 1.0000 sec

Line, Forming

$44.85 Operation G Trans Return Unclamp Part 1.0000 sec

Line, Forming

Design Profit ®

Page 35 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$44.85 Tool G Trans Return Tube Bending Equipment 0.0000 sec

Line, Forming

$44.85 Operation G Trans Return Clamp Part 3.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Return Bend Tube 1.0000 sec

Line, Forming

$44.85 Operation G Trans Return Unclamp Part 1.0000 sec

Line, Forming

$44.85 Operation G Trans Return CDI 1.0000 sec

Line, Forming

$44.85 Operation G Trans Return Clamp Part 3.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Return Bend Tube 1.0000 sec

Line, Forming

$44.85 Operation G Trans Return Unclamp Part 1.0000 sec

Line, Forming

$44.85 Operation G Trans Return CDI 1.0000 sec

Line, Forming

$44.85 Operation G Trans Return Clamp Part 3.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Return Bend Tube 1.0000 sec

Line, Forming

$44.85 Operation G Trans Return Unclamp Part 1.0000 sec

Line, Forming

$44.85 Operation G Trans Return CDI 1.0000 sec
Line, Forming

$44.85 Operation G Trans Return Clamp Part 3.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Return Bend Tube 1.0000 sec

Line, Forming

$44.85 Operation G Trans Return Unclamp Part 1.0000 sec

Line, Forming

$44.85 Operation G Trans Return CDI 1.0000 sec

Line, Forming

$44.85 Operation G Trans Return Clamp Part 3.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Return Bend Tube 1.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Return Crimp Tube 1.0000 sec

Line, Forming

$44.85 Operation G Trans Return Unclamp Part 1.0000 sec

Line, Forming

Design Profit ®

Page 36 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$44.85 Operation G Trans Return CDI 1.0000 sec

Line, Forming

$44.85 Operation G Trans Return Clamp Part 3.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Return Crimp Tube 1.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Return Taper Tube End 1.0000 sec

Line, Forming

$44.85 Operation G Trans Return Unclamp Part 1.0000 sec

Line, Forming

$44.85 Operation G Trans Return CDI 1.0000 sec

Line, Forming

$44.85 Operation G Trans Return Clamp Part 3.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Return Crimp Tube 1.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Return Taper Tube End 1.0000 sec

Line, Forming

$44.85 Operation G Trans Return Unclamp Part 1.0000 sec

Line, Forming

$35.51 Part G Trans Return G Label, Trans Return Line G Label, Trans 10.0000 sec 10.0000 sec

Line Asm Return Line

$35.51 Fastening G Trans Return Apply Label 3.0000 sec

Line Asm

$35.51 Subassembly G Trans Cooler G Trans Supply Line Asm G Trans Supply 7.0000 sec

Line Asm Line Asm

$35.51 Tool G Trans Supply First Fixture 0.0000 sec

Line Asm

$44.85 P.-P. Part G Trans Supply G Trans Supply Line, Forming G Trans Supply 3.0000 sec

Line Asm Line, Forming

$44.85 Tool G Trans Supply Tube Cutter 0.0000 sec

Line, Forming

$44.85 Part G Trans Supply G Trans Supply Line, Material G Trans Supply 0.0000 sec
Line, Forming Line, Material

- - - Start with Tube Stock - -

- - - Weight before machining 0.3022 - -

lbs

$44.85 Operation G Trans Supply Clamp Part 3.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Supply Cut to Length 1.0000 sec

Line, Forming

Design Profit ®

Page 37 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$44.85 Operation G Trans Supply Unclamp Part 1.0000 sec

Line, Forming

$44.85 Tool G Trans Supply Tube Bending Equipment 0.0000 sec

Line, Forming

$44.85 Operation G Trans Supply Clamp Part 3.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Supply Bend Tube 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply Unclamp Part 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply CDI 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply Clamp Part 3.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Supply Bend Tube 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply Unclamp Part Unclamp Part 1.0000 sec 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply CDI 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply Clamp Part 3.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Supply Bend Tube 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply Unclamp Part 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply CDI 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply Clamp Part 3.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Supply Bend Tube 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply Unclamp Part 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply CDI 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply Clamp Part 3.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Supply Bend Tube 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply Unclamp Part 1.0000 sec

Line, Forming
Design Profit ®

Page 38 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$44.85 Operation G Trans Supply CDI 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply Clamp Part 3.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Supply Bend Tube 1.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Supply Crimp Tube 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply Unclamp Part 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply CDI 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply Clamp Part 3.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Supply Crimp Tube 1.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Supply Taper Tube End 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply Unclamp Part 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply CDI 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply Clamp Part 3.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Supply Crimp Tube Crimp Tube 1.0000 sec 1.0000 sec

Line, Forming

$44.85 Material Mod. G Trans Supply Taper Tube End 1.0000 sec

Line, Forming

$44.85 Operation G Trans Supply Unclamp Part 1.0000 sec

Line, Forming

$35.51 Part G Trans Supply G Convolute Cover, Trans Supply G Convolute 7.0000 sec

Line Asm Line Cover, Trans 

Supply Line

$35.51 Fastening G Trans Supply Push On 2.0000 sec

Line Asm

$16.39 P.-P. Part G Trans Cooler G Trans Line Clamp G Trans Line 9.0000 sec

Line Asm Clamp

$16.39 Tool G Trans Line Injection Molding Machine 55-150 0.0000 sec

Clamp ton

$16.39 Part G Trans Line G Trans Line Clamp, Material G Trans Line 0.0000 sec

Clamp Clamp, Material

Design Profit ®

Page 39 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System
Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

- - - Raw Material Req 0.024 lbs from - -

Cost Sheet

- - - 10 Cavity Mold - -

- - - Box Size 58mm L x 48mm W x - -

12mm H

$35.51 Fastening G Trans Cooler Snap Together 1.0000 sec

Line Asm

$16.39 P.-P. Part G Trans Cooler G Trans Line Clamp for Bracket G Trans Line 9.0000 sec

Line Asm Clamp for Bracket

$16.39 Tool G Trans Line Injection Molding Machine 55-150 0.0000 sec

Clamp for Bracket ton

$16.39 Part G Trans Line G Trans Line Clamp for Bracket, G Trans Line 0.0000 sec

Clamp for Bracket Material Clamp for Bracket, 

Material

- - - Raw Material Req 0.029 lbs from - -

Cost Sheet

- - - 10 Cavity Mold - -

- - - Box Size 58mm L x 62mm W x - -

12mm H

$35.51 Fastening G Trans Cooler Snap Together 1.0000 sec

Line Asm

$15.50 P.-P. Part G Trans Cooler G Trans Line Bracket G Trans Line 7.0000 sec

Line Asm Bracket

$15.50 Tool G Trans Line Stamping Press 0-60 Ton 0.0000 sec

Bracket

$15.50 Part G Trans Line G Trans Line Bracket, Material G Trans Line 0.0000 sec

Bracket Bracket, Material

- - - Blank weight 0.305 lbs - -

- - - Press Size 60 Ton Prog. Die - -

- - - Part Size after stamping (104L by - -

52W by 28H)mm

$35.51 Fastening G Trans Cooler Push On 2.0000 sec

Line Asm

$35.51 Fastening G Trans Cooler Press Together 3.0000 sec

Line Asm, Trans

$16.39 P.-P. Part G Trans Cooler G Retainer, Trans to Cooler Line G Retainer, Trans 7.0000 sec

Line Asm, Trans to Cooler Line

$16.39 Tool G Retainer, Trans Injection Molding Machine 55-150 0.0000 sec

to Cooler Line ton

Design Profit ®

Page 40 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

$16.39 Part G Retainer, Trans G Retainer, Trans to Cooler Line, G Retainer, Trans 0.0000 sec

to Cooler Line Material to Cooler Line, 

Material

- - - Raw Material Req 0.025 lbs from - -

Cost Sheet
- - - 8 Cavity Mold - -

- - - Box Size 33mm L x 35mm W x - -

30mm H

$35.51 Fastening G Trans Cooler Press Together 3.0000 sec

Line Asm, Trans

$35.51 Operation G Trans Cooler CDI 1.0000 sec

Line Asm, Trans

$35.51 Multitouch G Trans Cooler G Regrab Exchanger Lines G Regrab 10.0000 sec 10.0000 sec

Line Asm, Trans Exchanger Lines

- - - Trans Line Bracket Mounting at - -

Trans

$35.51 Part G Trans Cooler H Nut, M6 KEPS H Nut, M6 KEPS 7.0000 sec

Line Asm, Trans

$35.51 Tool G Trans Cooler Power Tool 4.0000 sec

Line Asm, Trans

$35.51 Fastening G Trans Cooler Power Screw 4.0000 sec

Line Asm, Trans

- - - Mate Trans & FEM Lines - -

$83.31 Multitouch G Trans Cooler G Regrab Exchanger Lines G Regrab 10.0000 sec 10.0000 sec

System Exchanger Lines

$83.31 Fastening G Trans Cooler Press Together 3.0000 sec

System

$16.39 P.-P. Part G Trans Cooler G Retainer, Line to Line G Retainer, Line 7.0000 sec

System to Line

$16.39 Tool G Retainer, Line Injection Molding Machine 55-150 0.0000 sec

to Line ton

$16.39 Part G Retainer, Line G Retainer, Line to Line, Material G Retainer, Line 0.0000 sec

to Line to Line, Material

- - - Raw Material Req 0.030 lbs from - -

Cost Sheet

- - - 8 Cavity Mold - -

- - - Box Size 47mm L x 34mm W x - -

27mm H

$83.31 Fastening G Trans Cooler Press Together 3.0000 sec

System

Design Profit ®

Page 41 of #

Copyright 2010 © Design Profit, Inc.

G Trans Cooler System

Labor Type Parent Name

Symbol Name

Number Munro Score

Rate

Report Totals Count: ##
Design Profit

®

Page 42 of#

Copyright 2010 © Design Profit, Inc.
Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

0.0000 sec $0.00 $0.00 1 $0.00

- - - - -

3.0000 sec - $0.07 1 -

0.0000 sec $0.00 $0.00 1 $0.00

- - - - -

10.0000 sec - $0.10 1 -

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec - $0.03 1 -

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec - $0.04 1 -

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec - $0.04 1 -

0.0000 sec $0.00 $0.00 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

3.0000 sec - $0.04 1 -
0.0000 sec $0.00 $0.00 1 $0.00

0.7000 sec $0.07 $0.00 1 $0.07

- - - - -

- - - - -

- - - - -

5.0000 sec - $0.06 1 -

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec - $0.04 1 -

0.0000 sec $0.00 $0.00 1 $0.00

1.7000 sec $0.09 $0.02 1 $0.09

- - - - -

- - - - -

- - - - -

4.0000 sec - $0.05 1 -

0.0000 sec $0.00 $0.00 1 $0.00

0.0000 sec $0.18 $0.00 1 $0.18

- - - - -

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

0.0582 sec $0.00 $0.00 1 $0.00

5.0000 sec - $0.06 1 -

0.0000 sec $0.00 $0.00 1 $0.00

1.8000 sec $0.09 $0.02 1 $0.09
- - - - -

- - - - -

- - - - -

1.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec - $0.06 1 -

0.0000 sec $0.00 $0.00 1 $0.00

1.8000 sec $0.09 $0.02 1 $0.09

- - - - -

- - - - -

- - - - -

4.0000 sec - $0.05 1 -

0.0000 sec $0.00 $0.00 1 $0.00

0.0000 sec $0.18 $0.00 1 $0.18

- - - - -

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

0.0582 sec $0.00 $0.00 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec - $0.06 1 -

0.0000 sec $0.00 $0.00 1 $0.00

1.8000 sec $0.09 $0.02 1 $0.09

- - - - -

- - - - -

- - - - -
1.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec - $0.06 1 -

0.0000 sec $0.00 $0.00 1 $0.00

1.8000 sec $0.09 $0.02 1 $0.09

- - - - -

- - - - -

- - - - -

4.0000 sec - $0.05 1 -

0.0000 sec $0.00 $0.00 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

0.0000 sec $0.18 $0.00 1 $0.18

- - - - -

0.0582 sec $0.00 $0.00 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec - $0.06 1 -

0.0000 sec $0.00 $0.00 1 $0.00

1.8000 sec $0.09 $0.02 1 $0.09

- - - - -

- - - - -

- - - - -

1.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec - $0.06 1 -
0.0000 sec $0.00 $0.00 1 $0.00

1.8000 sec $0.09 $0.02 1 $0.09

- - - - -

- - - - -

- - - - -

4.0000 sec - $0.05 1 -

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

0.0000 sec $0.00 $0.00 1 $0.00

0.0000 sec $0.18 $0.00 1 $0.18

- - - - -

0.0582 sec $0.00 $0.00 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec - $0.06 1 -

0.0000 sec $0.00 $0.00 1 $0.00

1.8000 sec $0.09 $0.02 1 $0.09

- - - - -

- - - - -

- - - - -

1.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec - $0.06 1 -

0.0000 sec $0.00 $0.00 1 $0.00
1.8000 sec $0.09 $0.02 1 $0.09

- - - - -

- - - - -

- - - - -

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

4.0000 sec - $0.05 1 -

0.0000 sec $0.00 $0.00 1 $0.00

0.0000 sec $0.18 $0.00 1 $0.18

- - - - -

0.0582 sec $0.00 $0.00 1 $0.00

5.0000 sec - $0.06 1 -

0.0000 sec $0.00 $0.00 1 $0.00

1.8000 sec $0.09 $0.02 1 $0.09

- - - - -

- - - - -

- - - - -

3.0000 sec $0.00 $0.04 2 $0.00

3.0000 sec - $0.04 2 -

0.0000 sec $0.00 $0.00 2 $0.00

3.0000 sec - $0.03 2 -

0.0000 sec $0.00 $0.00 2 $0.00

- - - - -
Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

0.0000 sec $0.18 $0.00 2 $0.35

- - - - -

- - - - -

- - - - -

1.0000 sec $0.00 $0.01 2 $0.00

2.0000 sec $0.00 $0.01 2 $0.00

2.0000 sec $0.00 $0.01 2 $0.00

5.0000 sec $0.00 $0.03 2 $0.00

1.0000 sec $0.00 $0.01 2 $0.00

- - - - -

5.0000 sec $0.00 $0.03 2 $0.00

1.0000 sec $0.00 $0.01 2 $0.00

5.0000 sec $0.00 $0.03 2 $0.00

5.0000 sec $0.00 $0.03 2 $0.00

- - - - -

5.0000 sec $0.00 $0.03 2 $0.00
Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

2.0000 sec $0.00 $0.01 2 $0.00

2.0000 sec $0.00 $0.01 2 $0.00

2.0000 sec $0.00 $0.01 2 $0.00

- - - - -

2.0000 sec $0.00 $0.01 2 $0.00

1.0000 sec $0.00 $0.01 2 $0.00

2.0000 sec $0.00 $0.01 2 $0.00

2.0000 sec $0.00 $0.01 2 $0.00

2.0000 sec $0.00 $0.01 2 $0.00

2.0000 sec $0.00 $0.01 2 $0.00

- - - - -

2.0000 sec $0.00 $0.01 2 $0.00

2.0000 sec $0.00 $0.01 2 $0.00

5.0000 sec $0.00 $0.03 2 $0.00

2.0000 sec $0.00 $0.01 2 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

5.0000 sec $0.00 $0.03 2 $0.00

2.0000 sec $0.00 $0.01 6 $0.00
- - - - -

5.0000 sec $0.00 $0.03 2 $0.00

2.0000 sec $0.00 $0.01 2 $0.00

2.0000 sec $0.00 $0.01 2 $0.00

2.0000 sec $0.00 $0.01 2 $0.00

5.0000 sec $0.00 $0.03 2 $0.00

1.0000 sec $0.00 $0.01 2 $0.00

- - - - -

3.0000 sec $0.00 $0.02 2 $0.00

2.0000 sec $0.00 $0.01 2 $0.00

2.0000 sec $0.00 $0.01 2 $0.00

1.0000 sec $0.00 $0.01 2 $0.00

3.0000 sec $0.00 $0.03 2 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

3.0000 sec $0.00 $0.03 2 $0.00

2.0000 sec $0.00 $0.02 2 $0.00

3.0000 sec $0.00 $0.04 2 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

20.0000 sec $0.00 $0.26 1 $0.00
2.0000 sec $0.00 $0.03 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

5.0000 sec $0.00 $0.07 1 $0.00

2.0000 sec $0.00 $0.03 1 $0.00

6.0000 sec $0.05 $0.06 2 $0.09

2.0000 sec $0.00 $0.02 2 $0.00

6.0000 sec $0.00 $0.06 2 $0.00

4.0000 sec $0.00 $0.04 1 $0.00

4.0000 sec $0.00 $0.04 2 $0.00

9.0000 sec - $0.21 1 -

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec - $0.03 1 -

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec - $0.03 1 -

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec - $0.03 1 -

0.0000 sec $0.00 $0.00 1 $0.00
0.0000 sec $0.28 $0.00 1 $0.28

- - - - -

- - - - -

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 2 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00
1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00
1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 2 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

7.0000 sec $0.25 $0.09 1 $0.25

2.0000 sec $0.00 $0.02 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00
Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

9.0000 sec - $0.09 1 -

0.0000 sec $0.00 $0.00 1 $0.00

4.0000 sec - $0.04 1 -

0.0000 sec $0.00 $0.00 1 $0.00

8.0890 sec $0.19 $0.14 1 $0.19

- - - - -

5.0000 sec $0.12 $0.05 2 $0.24

2.0000 sec $0.00 $0.02 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

2.0000 sec $0.00 $0.02 1 $0.00

3.0000 sec - $0.03 1 -

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec - $0.03 1 -

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec - $0.01 1 -

0.0000 sec $0.00 $0.00 1 $0.00

- - - - -
Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

0.0000 sec $0.18 $0.00 1 $0.18

- - - - -

- - - - -

- - - - -

2.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec $0.00 $0.03 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec $0.00 $0.03 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec $0.00 $0.03 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

- - - - -

5.0000 sec $0.00 $0.03 1 $0.00

1.0000 sec $0.00 $0.01 4 $0.00

5.0000 sec $0.00 $0.03 1 $0.00

2.0000 sec $0.00 $0.01 4 $0.00

- - - - -

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

5.0000 sec $0.00 $0.03 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00
3.0000 sec $0.00 $0.02 1 $0.00

5.0000 sec $0.00 $0.03 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

2.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec $0.00 $0.01 1 $0.00

2.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec $0.05 $0.05 1 $0.05

1.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec - $0.05 1 -

0.0000 sec $0.00 $0.00 1 $0.00

1.0260 sec $0.01 $0.00 1 $0.01

- - - - -

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

- - - - -

- - - - -

1.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec - $0.05 1 -

0.0000 sec $0.00 $0.00 1 $0.00

0.5740 sec $0.01 $0.00 1 $0.01
- - - - -

- - - - -

- - - - -

1.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec $0.00 $0.05 1 $0.00

2.0000 sec $0.00 $0.02 1 $0.00

4.0000 sec $0.00 $0.04 1 $0.00

5.0000 sec $0.00 $0.05 1 $0.00

2.0000 sec $0.00 $0.02 1 $0.00

3.0000 sec $0.00 $0.03 1 $0.00

4.0000 sec $0.00 $0.04 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

5.0000 sec $0.00 $0.05 1 $0.00

10.0000 sec $0.10 $0.10 1 $0.10

3.0000 sec $0.00 $0.03 1 $0.00

7.0000 sec - $0.07 1 -

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec - $0.03 1 -

0.0000 sec $0.00 $0.00 1 $0.00
0.0000 sec $0.36 $0.00 1 $0.36

- - - - -

- - - - -

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00
1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00
3.0000 sec $0.00 $0.04 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00
Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00
Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

1.0000 sec $0.00 $0.01 2 $0.00

1.0000 sec $0.00 $0.01 2 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

7.0000 sec $0.25 $0.09 1 $0.25

2.0000 sec $0.00 $0.02 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

9.0000 sec - $0.09 1 -

0.0000 sec $0.00 $0.00 1 $0.00

4.0000 sec - $0.04 1 -

0.0000 sec $0.00 $0.00 1 $0.00

5.4061 sec $0.12 $0.09 1 $0.12

- - - - -

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

5.0000 sec $0.12 $0.05 2 $0.24

2.0000 sec $0.00 $0.02 1 $0.00
1.0000 sec $0.00 $0.01 1 $0.00

2.0000 sec $0.00 $0.02 1 $0.00

3.0000 sec - $0.03 1 -

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec - $0.03 1 -

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec - $0.01 1 -

0.0000 sec $0.00 $0.00 1 $0.00

- - - - -

0.0000 sec $0.18 $0.00 1 $0.18

- - - - -

- - - - -

- - - - -

2.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec $0.00 $0.03 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

1.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec $0.00 $0.03 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec $0.00 $0.03 1 $0.00
1.0000 sec $0.00 $0.01 1 $0.00

- - - - -

5.0000 sec $0.00 $0.03 1 $0.00

1.0000 sec $0.00 $0.01 4 $0.00

5.0000 sec $0.00 $0.03 1 $0.00

2.0000 sec $0.00 $0.01 4 $0.00

- - - - -

5.0000 sec $0.00 $0.03 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.02 1 $0.00

5.0000 sec $0.00 $0.03 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

1.0000 sec $0.00 $0.01 1 $0.00

2.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec $0.00 $0.01 1 $0.00

2.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec $0.05 $0.05 1 $0.05

1.0000 sec $0.00 $0.01 1 $0.00
5.0000 sec - $0.05 1 -

0.0000 sec $0.00 $0.00 1 $0.00

1.0260 sec $0.01 $0.00 1 $0.01

- - - - -

- - - - -

- - - - -

1.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec - $0.05 1 -

0.0000 sec $0.00 $0.00 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

0.5740 sec $0.01 $0.00 1 $0.01

- - - - -

- - - - -

- - - - -

1.0000 sec $0.00 $0.01 1 $0.00

5.0000 sec $0.00 $0.05 1 $0.00

2.0000 sec $0.00 $0.02 1 $0.00

4.0000 sec $0.00 $0.04 1 $0.00

5.0000 sec $0.00 $0.05 1 $0.00

2.0000 sec $0.00 $0.02 1 $0.00

3.0000 sec $0.00 $0.03 1 $0.00

4.0000 sec $0.00 $0.04 1 $0.00
5.0000 sec $0.00 $0.05 1 $0.00

3.0000 sec $0.00 $0.03 1 $0.00

9.0000 sec - $0.09 2 -

0.0000 sec $0.00 $0.00 2 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

1.2520 sec $0.05 $0.01 2 $0.10

- - - - -

- - - - -

- - - - -

2.0000 sec $0.00 $0.02 1 $0.00

2.0000 sec $0.00 $0.02 1 $0.00

2.0000 sec $0.00 $0.02 1 $0.00

9.0000 sec - $0.09 1 -

0.0000 sec $0.00 $0.00 1 $0.00

1.2690 sec $0.03 $0.01 1 $0.03

- - - - -

- - - - -

- - - - -

2.0000 sec $0.00 $0.02 1 $0.00

7.0000 sec $0.04 $0.07 2 $0.07
2.0000 sec $0.00 $0.02 2 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

2.0000 sec $0.00 $0.05 2 $0.00

2.0000 sec $0.00 $0.05 1 $0.00

10.0000 sec $0.00 $0.23 2 $0.00

3.0000 sec $0.00 $0.07 2 $0.00

2.0000 sec $0.00 $0.05 1 $0.00

3.0000 sec $0.00 $0.07 1 $0.00

7.0000 sec $0.00 $0.16 2 $0.00

- - - - -

6.0000 sec - $0.14 1 -

0.0000 sec $0.00 $0.00 1 $0.00

- - - - -

3.0000 sec - $0.03 2 -

0.0000 sec $0.00 $0.00 2 $0.00

3.0000 sec - $0.03 2 -

0.0000 sec $0.00 $0.00 2 $0.00

3.0000 sec - $0.03 2 -

0.0000 sec $0.00 $0.00 2 $0.00

3.0000 sec - $0.01 2 -
Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

0.0000 sec $0.00 $0.00 2 $0.00

- - - - -

0.0000 sec $0.10 $0.00 2 $0.19

- - - - -

- - - - -

- - - - -

2.0000 sec $0.00 $0.01 2 $0.00

5.0000 sec $0.00 $0.03 2 $0.00

1.0000 sec $0.00 $0.01 2 $0.00

5.0000 sec $0.00 $0.03 2 $0.00

1.0000 sec $0.00 $0.01 2 $0.00

5.0000 sec $0.00 $0.03 2 $0.00

1.0000 sec $0.00 $0.01 2 $0.00

- - - - -

5.0000 sec $0.00 $0.03 2 $0.00

1.0000 sec $0.00 $0.01 4 $0.00

5.0000 sec $0.00 $0.03 2 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

2.0000 sec $0.00 $0.01 2 $0.00
- - - - -

5.0000 sec $0.00 $0.03 2 $0.00

1.0000 sec $0.00 $0.01 4 $0.00

5.0000 sec $0.00 $0.03 2 $0.00

2.0000 sec $0.00 $0.01 2 $0.00

- - - - -

5.0000 sec $0.00 $0.03 2 $0.00

1.0000 sec $0.00 $0.01 2 $0.00

3.0000 sec $0.00 $0.02 2 $0.00

5.0000 sec $0.00 $0.03 2 $0.00

1.0000 sec $0.00 $0.01 2 $0.00

2.0000 sec $0.00 $0.01 2 $0.00

1.0000 sec $0.00 $0.01 2 $0.00

2.0000 sec $0.00 $0.01 2 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

3.0000 sec $0.00 $0.01 2 $0.00

5.0000 sec $0.00 $0.01 2 $0.00

2.0000 sec $0.00 $0.01 2 $0.00

5.0000 sec $0.05 $0.05 2 $0.09
1.0000 sec $0.00 $0.01 2 $0.00

5.0000 sec - $0.05 2 -

0.0000 sec $0.00 $0.00 2 $0.00

1.0260 sec $0.01 $0.00 2 $0.01

- - - - -

- - - - -

- - - - -

1.0000 sec $0.00 $0.01 2 $0.00

5.0000 sec - $0.05 2 -

0.0000 sec $0.00 $0.00 2 $0.00

0.5740 sec $0.01 $0.00 2 $0.01

- - - - -

- - - - -

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

- - - - -

1.0000 sec $0.00 $0.01 2 $0.00

5.0000 sec $0.00 $0.05 2 $0.00

6.0000 sec $0.04 $0.06 2 $0.08

2.0000 sec $0.00 $0.02 2 $0.00

4.0000 sec $0.00 $0.04 1 $0.00

4.0000 sec $0.00 $0.04 2 $0.00
4.0000 sec - $0.04 1 -

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec - $0.03 1 -

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec - $0.03 1 -

0.0000 sec $0.00 $0.00 1 $0.00

0.0000 sec $0.26 $0.00 1 $0.26

- - - - -

- - - - -

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 2 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 2 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00
3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

10.0000 sec $0.10 $0.10 1 $0.10

3.0000 sec $0.00 $0.03 1 $0.00

7.0000 sec - $0.07 1 -

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec - $0.03 1 -

0.0000 sec $0.00 $0.00 1 $0.00

0.0000 sec $0.19 $0.00 1 $0.19
- - - - -

- - - - -

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

1.0000 sec $0.00 $0.01 1 $0.00

0.0000 sec $0.00 $0.00 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00
Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

3.0000 sec $0.00 $0.04 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

7.0000 sec $0.03 $0.07 1 $0.03

2.0000 sec $0.00 $0.02 1 $0.00

9.0000 sec - $0.09 1 -

0.0000 sec $0.00 $0.00 1 $0.00

1.5250 sec $0.04 $0.01 1 $0.04
Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

- - - - -

- - - - -

- - - - -

1.0000 sec $0.00 $0.01 1 $0.00

9.0000 sec - $0.09 1 -

0.0000 sec $0.00 $0.00 1 $0.00

1.5280 sec $0.05 $0.01 1 $0.05

- - - - -

- - - - -

- - - - -

1.0000 sec $0.00 $0.01 1 $0.00

7.0000 sec - $0.07 1 -

0.0000 sec $0.00 $0.00 1 $0.00

0.7000 sec $0.15 $0.00 1 $0.15

- - - - -

- - - - -

- - - - -

2.0000 sec $0.00 $0.02 1 $0.00

3.0000 sec $0.00 $0.03 2 $0.00

7.0000 sec - $0.07 2 -

0.0000 sec $0.00 $0.00 2 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

1.2770 sec $0.04 $0.01 2 $0.07

- - - - -
- - - - -

- - - - -

3.0000 sec $0.00 $0.03 2 $0.00

1.0000 sec $0.00 $0.01 1 $0.00

10.0000 sec $0.00 $0.10 2 $0.00

- - - - -

7.0000 sec $0.00 $0.07 2 $0.00

4.0000 sec $0.00 $0.04 1 $0.00

4.0000 sec $0.00 $0.04 2 $0.00

- - - - -

10.0000 sec $0.00 $0.23 2 $0.00

3.0000 sec $0.00 $0.07 2 $0.00

7.0000 sec - $0.16 2 -

0.0000 sec $0.00 $0.00 2 $0.00

1.2690 sec $0.04 $0.01 2 $0.09

- - - - -

- - - - -

- - - - -

3.0000 sec $0.00 $0.07 2 $0.00

Actual Time Piece Cost Total Labor Qty Piece Co

Cost (Total) (Total)

708 $6.38

Page:1 of 6 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

09 Accessory Drive Subsystem

1 00 Assembly of Accessory Drive Subsystem #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - #REF! #REF! #REF! #REF!

2 01 Pulleys $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

3 02 Tensioners #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - $ 4.75 $ 2.64 $ 3.16 $ 10.55

4 03 Guides $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

5 05 Belts $ 4.89 $ 1.09 $ 4.89 $ 10.86 $ 0.05 $ 0.71 $ 0.65 $ 0.27 $ 1.68 $ 0.02 $ 12.56 $ - $ - $ - $ 2.85 $ 0.63 $ 2.85 $ 6.33

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Item

Subsystem

System 

ED&T/R&D

(x1000)

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Investment

(X1000)

BASE TECHNOLOG

Technology Level: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

6 65 Adaptors $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

7 70 Pipes, Hoses, Ducting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 75 Brackets #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - #REF! #REF! #REF! #REF!

9 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 90 Bearings Elements Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 95 Tools $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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

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

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

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

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

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

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:2 of 6 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Item

Subsystem

System 

ED&T/R&D

(x1000)

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Investment

(X1000)

BASE TECHNOLOG

Technology Level: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

SUBSYSTEM ROLL-UP #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - #REF! #REF! #REF! #REF!

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

09 Accessory Drive Subsystem

1 00

2 01

3 02

4 03

5 05

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

$ - $ - $ - $ - $ - $ - #REF! $ - $ - $ - #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ -

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

$ 0.05 $ 0.69 $ 0.63 $ 0.26 $ 1.63 $ 0.04 $ 12.22 $ - $ - $ - #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ -

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

$ 0.03 $ 0.41 $ 0.38 $ 0.16 $ 0.98 $ 0.02 $ 7.33 $ - $ - $ - $ 2.04 $ 0.45 $ 2.04 $ 4.53 $ 0.02 $ 0.29 $ 0.27 $ 0.11 $ 0.70 $ - $ 5.23 $ - $ -

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

6 65

7 70

8 75

9 80

10 85

11 90

12 95

13 99

0 0

0 0

0 0

0 0

0 0

0 0

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

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

#REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ -

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

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

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

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

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

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

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

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

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

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

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

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

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:4 of 6 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

#REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ -

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

09 Accessory Drive Subsystem

1 00

2 01

3 02

4 03

5 05

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

$ -

$ -

$ -

$ -

$ -

Investment(X1

000)

6 65

7 70

8 75

9 80

10 85

11 90

12 95

13 99

0 0

0 0

0 0

0 0

0 0

0 0

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

0 0 $ -

09000064810ec171.xls

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

Author: G. Kolwich

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

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

Investment(X1

000)

$ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:1 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

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

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

9 Accessory Drive Subsystem

1 00 Assembly of Accessory Drive Subsystem #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

A Assembly of Accessory Drive Subsystem 01 09 00 - N0402- 01 1 Full 1

Only includes tensioner, tensioner 

spring assembly, and 

alternator/tensioner mounting 

bracket.

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

2 01 Pulleys $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Sub-Subsystem

Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

System 

ED&T/R&D

(x1000)

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description

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: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

2 01 Pulleys $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

3 02 Tensioners #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

A V Tensioner, Belt 01 09 02 - N0402- 01 1 Full 1 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

B V Belt Tensioner Spring Assembly 01 09 02 - N0402- 02 1 Full 1 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

4 03 Guides $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

5 05 Belts $ 4.89 $ 1.09 $ 4.89 $ 10.86 $ 0.05 $ 0.71 $ 0.65 $ 0.27 $ 1.68 $ 0.02 $ 12.56 $ -

A Belt - Accessory Drive 01 09 05 - N0402- 01 1 Full 0.5

Scaled Saturn Parts service number 

by factor of 2. TMC (45/10/45), Markup (0.5/6.5/6.0/2.50) 15.5%*TMC

$ 4.89 $ 1.09 $ 4.89 $ 10.86 $ 0.05 $ 0.71 $ 0.65 $ 0.27 $ 1.68 $ 0.02 $ 12.56 $ -

6 65 Adaptors $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

7 70 Pipes, Hoses, Ducting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

8 75 Brackets #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

A V Bracket, Alternator (and Tensioner Mounting) 01 09 75 - N0402- 01 1 Full 1 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

9 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A V Large Bolt, Alt Bracket 01 09 80 - N0402- 01 1 Full 1

PIA to Assembly of Accessory A V Large Bolt, Alt Bracket 01 09 80 - N0402- 01 1 Full 1 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

PIA to Assembly of Accessory 

Drive $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:2 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

Sub-Subsystem

Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

System 

ED&T/R&D

(x1000)

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description

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: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

B V Bolt, Small, Alt Bracket 01 09 80 - N0402- 02 1 Full 1

PIA to Assembly of Accessory 

Drive

C V Bolt, Medium, Alt Bracket 01 09 80 - N0402- 03 2 Full 1

PIA to Assembly of Accessory 

Drive

D V Bolt Tensioner 01 09 80 - N0402- 04 1 Full 1

PIA to Assembly of Accessory 

Drive

E V Bolt, Belt Damper, Short 01 09 80 - N0402- 05 1 Full 1

PIA to Assembly of Accessory 

Drive

F V Bolt, Belt Damper Long 01 09 80 - N0402- 06 1 Full 1

PIA to Assembly of Accessory 

Drive

10 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

11 90 Bearings Elements Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

12 95 Tools $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

13 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

Complete Subsystem Quote 

(Yes/No) No

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:3 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

9 Accessory Drive Subsystem

1 00 Assembly of Accessory Drive Subsystem 

A Assembly of Accessory Drive Subsystem 01 09 00 - N0402- 01 1 Full 1

Only includes tensioner, tensioner 

spring assembly, and 

alternator/tensioner mounting 

bracket.

2 01 Pulleys

Sub-Subsystem

Part Number

QTY/ Subsystem

Notes

Subassembly

Component

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

2 01 Pulleys

3 02 Tensioners

A V Tensioner, Belt 01 09 02 - N0402- 01 1 Full 1

B V Belt Tensioner Spring Assembly 01 09 02 - N0402- 02 1 Full 1

4 03 Guides

5 05 Belts

A Belt - Accessory Drive 01 09 05 - N0402- 01 1 Full 0.5

Scaled Saturn Parts service number 

by factor of 2. TMC (45/10/45), Markup (0.5/6.5/6.0/2.50) 15.5%*TMC

6 65 Adaptors

7 70 Pipes, Hoses, Ducting

8 75 Brackets

A V Bracket, Alternator (and Tensioner Mounting) 01 09 75 - N0402- 01 1 Full 1

9 80 Boltings

A V Large Bolt, Alt Bracket 01 09 80 - N0402- 01 1 Full 1

PIA to Assembly of Accessory 

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

A V Large Bolt, Alt Bracket 01 09 80 - N0402- 01 1 Full 1 $ - $ -

PIA to Assembly of Accessory 

Drive $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:4 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Sub-Subsystem

Part Number

QTY/ Subsystem

Notes

Subassembly

Component

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

B V Bolt, Small, Alt Bracket 01 09 80 - N0402- 02 1 Full 1

PIA to Assembly of Accessory 

Drive

C V Bolt, Medium, Alt Bracket 01 09 80 - N0402- 03 2 Full 1

PIA to Assembly of Accessory 

Drive

D V Bolt Tensioner 01 09 80 - N0402- 04 1 Full 1

PIA to Assembly of Accessory 

Drive

E V Bolt, Belt Damper, Short 01 09 80 - N0402- 05 1 Full 1

PIA to Assembly of Accessory 

Drive

F V Bolt, Belt Damper Long 01 09 80 - N0402- 06 1 Full 1

PIA to Assembly of Accessory 

Drive

10 85 Sealing Elements

Investment

(X1000)

Tooling 

(x1000)

$ - $ -

$ - $ -

11 90 Bearings Elements Misc

12 95 Tools

13 99 Miscellaneous

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

Complete Subsystem Quote 

(Yes/No) No

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:1 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

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

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

9 Accessory Drive Subsystem

1 00 Assembly of Accessory Drive Subsystem #REF! #REF! #REF! #REF! $ - $ - $ - $ - $ - $ - #REF! $ -

A Assembly of Accessory Drive Subsystem 01 09 00 - B0402 - 01 1 Full 1

Used Vue hybrid cost sheet and 

ammended via service drawings #REF! #REF! #REF! #REF! $ - $ - $ - $ - $ - $ - #REF! $ -

2 01 Pulleys $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

3 02 Tensioners $ 4.75 $ 2.64 $ 3.16 $ 10.55 $ 0.05 $ 0.69 $ 0.63 $ 0.26 $ 1.63 $ 0.04 $ 12.22 $ -

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem

Technology Level: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

3 02 Tensioners $ 4.75 $ 2.64 $ 3.16 $ 10.55 $ 0.05 $ 0.69 $ 0.63 $ 0.26 $ 1.63 $ 0.04 $ 12.22 $ -

A Tensioner - 2.2 Liter Saturn Vue 01 09 02 - B0402 - 01 1 Full 0.18

Scaled service price based on ratio 

developed for Vue Hybrid developed 

cost versus service cost (5.6 Factor). 

Kept same cost element binning 

ratios.

$ 4.75 $ 2.64 $ 3.16 $ 10.55 $ 0.05 $ 0.69 $ 0.63 $ 0.26 $ 1.63 $ 0.04 $ 12.22 $ -

4 03 Guides $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

5 05 Belts $ 2.85 $ 0.63 $ 2.85 $ 6.33 $ 0.03 $ 0.41 $ 0.38 $ 0.16 $ 0.98 $ 0.02 $ 7.33 $ -

A Belt - Accessory Drive 2.2 L Saturn Vue 01 09 05 - B0402 - 01 1 Full 0.5

Scaled Saturn Parts service number 

by factor of 2. TMC (45/10/45), Markup (0.5/6.5/6.0/2.50) 15.5%*TMC

$ 2.85 $ 0.63 $ 2.85 $ 6.33 $ 0.03 $ 0.41 $ 0.38 $ 0.16 $ 0.98 $ 0.02 $ 7.33 $ -

6 65 Adaptors $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

7 70 Pipes, Hoses, Ducting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 75 Brackets #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

A V Bracket, Alternator (and Tensioner Mounting) 01 09 75 - B0402 - 01 1 Full 0.75

Scaled Vue Hybrid 

developed cost to account 

for less mounting content.

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

9 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A V Large Bolt, Alt Bracket 01 09 80 - B0402 - 01 1 Full 1

PIA to Assembly of Accessory 

Drive $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:2 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem

Technology Level: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

B V Bolt, Small, Alt Bracket 01 09 80 - B0402 - 02 1 Full 1

PIA to Assembly of Accessory 

Drive

C V Bolt, Medium, Alt Bracket 01 09 80 - B0402 - 03 1 Full 1

PIA to Assembly of Accessory 

Drive

D V Bolt Tensioner 01 09 80 - B0402 - 04 1 Full 1

PIA to Assembly of Accessory 

Drive

10 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 90 Bearings Elements Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 95 Tools $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ -

NOTES:

1.

Complete Subsystem Quote 

(Yes/No) N

 = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:3 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

0

9 Accessory Drive Subsystem

1 00 Assembly of Accessory Drive Subsystem 

A Assembly of Accessory Drive Subsystem 01 09 00 - B0402 - 01 1 Full 1

Used Vue hybrid cost sheet and 

ammended via service drawings

2 01 Pulleys

3 02 Tensioners

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

3 02 Tensioners

A Tensioner - 2.2 Liter Saturn Vue 01 09 02 - B0402 - 01 1 Full 0.18

Scaled service price based on ratio 

developed for Vue Hybrid developed 

cost versus service cost (5.6 Factor). 

Kept same cost element binning 

ratios.

4 03 Guides

5 05 Belts

A Belt - Accessory Drive 2.2 L Saturn Vue 01 09 05 - B0402 - 01 1 Full 0.5

Scaled Saturn Parts service number 

by factor of 2. TMC (45/10/45), Markup (0.5/6.5/6.0/2.50) 15.5%*TMC

6 65 Adaptors

7 70 Pipes, Hoses, Ducting

8 75 Brackets

A V Bracket, Alternator (and Tensioner Mounting) 01 09 75 - B0402 - 01 1 Full 0.75

Scaled Vue Hybrid 

developed cost to account 

for less mounting content.

9 80 Boltings

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

A V Large Bolt, Alt Bracket 01 09 80 - B0402 - 01 1 Full 1

PIA to Assembly of Accessory 

Drive $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:4 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Mild Hybrid, Start-Stop Technology

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

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

B V Bolt, Small, Alt Bracket 01 09 80 - B0402 - 02 1 Full 1

PIA to Assembly of Accessory 

Drive

C V Bolt, Medium, Alt Bracket 01 09 80 - B0402 - 03 1 Full 1

PIA to Assembly of Accessory 

Drive

D V Bolt Tensioner 01 09 80 - B0402 - 04 1 Full 1

PIA to Assembly of Accessory 

Drive

10 85 Sealing Elements

11 90 Bearings Elements Misc

Investment

(X1000)

Tooling 

(x1000)

$ - $ -

$ - $ -

12 95 Tools

13 99 Miscellaneous

NOTES:

1.

Complete Subsystem Quote 

(Yes/No) N

 = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

$ - $ -

$ - $ -

$ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

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

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

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Part Number: Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

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

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

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

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

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

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Part Number: Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Part Number: Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Part Number: Weekly Component Volume: Packaging Specification:

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

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