Not Included in Analysis

*2 Nuts to secure inlet and outlet lines to compressor (Studs accounted for)

* Mounting Bracket and fastening hardware to engine



Page:1 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

120300 Refrigeration/Air Conditioning Subsystem

1 00 Assembly of Refrigeration/Air Conditioning Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 01 AC Compressor $ 148.86 $ 23.86 $ 43.32 $ 216.04 $ 1.85 $ 14.57 $ 13.38 $ 5.46 $ 35.25 $ - $ 251.30 Scale Ford Fusion HEV AC compressor 

price by vehicle interior volume ratio. 

Sub-Subsystem Description Scaling Parameter(s) Description Notes

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Total 

Packaging 

Cost 

(Component

/ Assembly)

NEW TECHNOLOGY GENERAL PAR

2010 Ford Fusion, 2.5L Atkinson Cycle

(Motor 60kW, Battery 275V, Nominal Pack C

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Technology Level: Power-Split HEV Technology

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

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

3 02 Condenser $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

4 05 AC Lines, Receiver Drier and Accumulator $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

5 10 Plugs $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

6 70 Pipes, Hoses, Ducting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

7 75 Brackets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 97 Vehicle Wiring - Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SUBSYSTEM ROLL-UP $ 148.86 $ 23.86 $ 43.32 $ 216.04 $ 1.85 $ 14.57 $ 13.38 $ 5.46 $ 35.25 $ - $ 251.30 $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:2 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

Sub-Subsystem Description Scaling Parameter(s) Description Notes

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Total 

Packaging 

Cost 

(Component

/ Assembly)

NEW TECHNOLOGY GENERAL PAR

2010 Ford Fusion, 2.5L Atkinson Cycle

(Motor 60kW, Battery 275V, Nominal Pack C

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Technology Level: Power-Split HEV Technology

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

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

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:3 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

Sub-Subsystem Description Scaling Parameter(s) Description Notes

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Total 

Packaging 

Cost 

(Component

/ Assembly)

NEW TECHNOLOGY GENERAL PAR

2010 Ford Fusion, 2.5L Atkinson Cycle

(Motor 60kW, Battery 275V, Nominal Pack C

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Technology Level: Power-Split HEV Technology

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

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

Material Labor Burden End Item 

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

05 Cylinder Blocks

A1 01 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B1 02 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

C1 03 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

D1 04 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

2 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

E1 65 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

F1 66 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

G1 67 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

H1 70 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

BASE 

TECHNO

LOGY 

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

BASE TECHNOLOGY PACKAGE CO

Item

Subsystem

Sub-Subsystem

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Markup

H1 70 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:4 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

Sub-Subsystem Description Scaling Parameter(s) Description Notes

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Total 

Packaging 

Cost 

(Component

/ Assembly)

NEW TECHNOLOGY GENERAL PAR

2010 Ford Fusion, 2.5L Atkinson Cycle

(Motor 60kW, Battery 275V, Nominal Pack C

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Technology Level: Power-Split HEV Technology

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

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

I1 75 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

J1 80 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

K1 85 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

L1 90 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

M1 99 $ - $ - $ - $ $ - $ - $ - $ - $ - $ $ - $ - $ $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

N1 00 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SU

BS

YS

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

Material Labor Burden End Item 

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

05 Cylinder Blocks

A1 01 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B1 02 $ 148.86 $ 23.86 $ 43.32 $ 216.04 $ 1.85 $ 14.57 $ 13.38 $ 5.46 $ 35.25 $ - $ 251.30

C1 03 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

D1 04 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

TECHNO

LOGY 

PACKAG

INCREMENTAL COST TO UPGRADE TO NEW 

Item

Subsystem

Sub-Subsystem

E1 65 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:5 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

Sub-Subsystem Description Scaling Parameter(s) Description Notes

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Total 

Packaging 

Cost 

(Component

/ Assembly)

NEW TECHNOLOGY GENERAL PAR

2010 Ford Fusion, 2.5L Atkinson Cycle

(Motor 60kW, Battery 275V, Nominal Pack C

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Technology Level: Power-Split HEV Technology

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

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

F1 66 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

G1 67 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

H1 70 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

I1 75 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

J1 80 $ - $ - $ - $ $ - $ - $ - $ - $ - $ $ - $ - $ $ -

K1 85 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

L1 90 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

M1 99 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

N1 00 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SU

BS

YS

#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:6 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

120300 Refrigeration/Air Conditioning Subsystem

1 00

2 01

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value Material Labor Burden

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

0.89 $ 224.32 0.95 $ 238.30 1.02 $ 256.42 $ 1.27 $ 320.15 $ 1.17 $ 293.54 1.12 $ 282.62 $ - $ - $ - $ 24.10 $ 19.18 $ 25.92

Manufacturing 

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

System 

ED&T/R&D

(x1000)

NEW TECHNOLOGY GENERAL PART INFORMATION:

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

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

Tooling 

(x1000)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

Small/Compact Vehicle Segment 

Passenger 2-5

(e.g. Ford Focus)

Investment

(X1000)

3 02

4 05

5 10

6 70

7 75

8 80

9 85

10 97

11 99

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

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

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

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

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

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

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

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

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

$ 224.32 $ 238.30 $ 256.42 $ 320.15 $ 293.54 $ 282.62 $ - $ - $ - $ 24.10 $ 19.18 $ 25.92

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:7 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value Material Labor Burden

Manufacturing 

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

System 

ED&T/R&D

(x1000)

NEW TECHNOLOGY GENERAL PART INFORMATION:

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

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

Tooling 

(x1000)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

Small/Compact Vehicle Segment 

Passenger 2-5

(e.g. Ford Focus)

Investment

(X1000)

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:8 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value Material Labor Burden

Manufacturing 

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

System 

ED&T/R&D

(x1000)

NEW TECHNOLOGY GENERAL PART INFORMATION:

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

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

Tooling 

(x1000)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

Small/Compact Vehicle Segment 

Passenger 2-5

(e.g. Ford Focus)

Investment

(X1000)

05 Cylinder Blocks

A1 01

2

B1 02

2

C1 03

2

D1 04

2

E1 65

2

F1 66

2

G1 67

2

H1 70

BASE 

TECHNO

LOGY 

Item

Subsystem

Sub-Subsystem

Material Labor Burden

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

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

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

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

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

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

$ - $ - $ - #REF! #REF! #REF!

$ - $ - $ - #REF! #REF! #REF!

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

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

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

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

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

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

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

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

Manufacturing 

BASE TECHNOLOGY PACKAGE COST INFORMATION

H1 70

2

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

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

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:9 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

I1 75

2

J1 80

2

K1 85

2

L1 90

2

M1 99

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value Material Labor Burden

Manufacturing 

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

System 

ED&T/R&D

(x1000)

NEW TECHNOLOGY GENERAL PART INFORMATION:

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

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

Tooling 

(x1000)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

Small/Compact Vehicle Segment 

Passenger 2-5

(e.g. Ford Focus)

Investment

(X1000)

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

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

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

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

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

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

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

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

M1 99

2

N1 00

2

SU

BS

YS

05 Cylinder Blocks

A1 01

B1 02

C1 03

D1 04

TECHNO

LOGY 

PACKAG

Item

Subsystem

Sub-Subsystem

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

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

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

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

$ - $ - $ - #REF! #REF! #REF!

Material Labor Burden

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

$ - $ - $ - $ 24.10 $ 19.18 $ 25.92

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

$ - $ - $ - #REF! #REF! #REF!

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Investment

(X1000)

Manufacturing 

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

E1 65 $ - $ - $ - $ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:10 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

F1 66

G1 67

H1 70

I1 75

J1 80

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value Material Labor Burden

Manufacturing 

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

System 

ED&T/R&D

(x1000)

NEW TECHNOLOGY GENERAL PART INFORMATION:

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

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

Tooling 

(x1000)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

Small/Compact Vehicle Segment 

Passenger 2-5

(e.g. Ford Focus)

Investment

(X1000)

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

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

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

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

J1 80

K1 85

L1 90

M1 99

N1 00

SU

BS

YS

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

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

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

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

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

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

$ - $ - $ - #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:11 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

120300 Refrigeration/Air Conditioning Subsystem

1 00

2 01

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

End Item 

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

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

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

$ 69.20 $ 0.58 $ 6.52 $ 5.56 $ 1.89 $ 14.56 $ - $ 83.75 Scale Ford Fusion Base AC compressor 

price by vehicle interior volume ratio. 0.89 $ 74.76 0.95 $ 79.42 1.02 $ 85.46

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Scaling Parameter(s) Description Notes

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Small/Compact Vehicle Segment 

Passenger 2-5

Total Markup (e.g. Ford Focus)

Cost 

(Component/ 

Assembly)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

3 02

4 05

5 10

6 70

7 75

8 80

9 85

10 97

11 99

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

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

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

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

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

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

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

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

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

$ 69.20 $ 0.58 $ 6.52 $ 5.56 $ 1.89 $ 14.56 $ - $ 83.75 $ - $ 74.76 $ 79.42 $ 85.46

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:12 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

End Item 

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

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Scaling Parameter(s) Description Notes

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Small/Compact Vehicle Segment 

Passenger 2-5

Total Markup (e.g. Ford Focus)

Cost 

(Component/ 

Assembly)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:13 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

End Item 

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

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Scaling Parameter(s) Description Notes

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Small/Compact Vehicle Segment 

Passenger 2-5

Total Markup (e.g. Ford Focus)

Cost 

(Component/ 

Assembly)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

05 Cylinder Blocks

A1 01

2

B1 02

2

C1 03

2

D1 04

2

E1 65

2

F1 66

2

G1 67

2

H1 70

BASE 

TECHNO

LOGY 

Item

Subsystem

Sub-Subsystem

End Item 

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

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

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

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

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

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

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

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

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

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

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

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

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

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

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

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLOGY PACKAGE COST INFORMATION

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

H1 70

2

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

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

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:14 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

I1 75

2

J1 80

2

K1 85

2

L1 90

2

M1 99

End Item 

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

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Scaling Parameter(s) Description Notes

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Small/Compact Vehicle Segment 

Passenger 2-5

Total Markup (e.g. Ford Focus)

Cost 

(Component/ 

Assembly)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

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

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

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

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

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

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

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

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

M1 99 $ - $ - $ -

2

N1 00

2

SU

BS

YS

05 Cylinder Blocks

A1 01

B1 02

C1 03

D1 04

TECHNO

LOGY 

PACKAG

Item

Subsystem

Sub-Subsystem

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

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

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

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

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

End Item 

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

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

$ 69.20 $ 0.58 $ 6.52 $ 5.56 $ 1.89 $ 14.56 $ - $ 83.75

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

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

Markup Total 

Packaging 

Cost 

(Component

/ Assembly)

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

E1 65 $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:15 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

F1 66

G1 67

H1 70

I1 75

J1 80

End Item 

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

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Scaling Parameter(s) Description Notes

Sub-Compact Vehicle Segment

Passenger 2-4

(e.g. Ford Fiesta)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Small/Compact Vehicle Segment 

Passenger 2-5

Total Markup (e.g. Ford Focus)

Cost 

(Component/ 

Assembly)

Mid Size/Vehicle Segment

Passenger 4-6

(e.g. Ford Fusion)

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

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

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

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

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

J1 80 $ - $ - $ -

K1 85

L1 90

M1 99

N1 00

SU

BS

YS

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

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

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

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

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

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

#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:16 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

120300 Refrigeration/Air Conditioning Subsystem

1 00

2 01

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value Material Labor Burden End Item 

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

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

$ 1.27 $ 106.70 $ 1.17 $ 97.83 1.12 $ 94.19 $ 124.76 $ 4.68 $ 17.40 $ 146.85 $ 1.27 $ 8.04 $ 7.82 $ 3.57 $ 20.70 $ - $ 167.54

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

3 02

4 05

5 10

6 70

7 75

8 80

9 85

10 97

11 99

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

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

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

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

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

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

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

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

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

$ 106.70 $ 97.83 $ 94.19 ###### $ 4.68 $ 17.40 $ 146.85 $ 1.27 $ 8.04 $ 7.82 $ 3.57 $ 20.70 $ - $ 167.54

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:17 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value Material Labor Burden End Item 

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

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:18 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value Material Labor Burden End Item 

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

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

05 Cylinder Blocks

A1 01

2

B1 02

2

C1 03

2

D1 04

2

E1 65

2

F1 66

2

G1 67

2

H1 70

BASE 

TECHNO

LOGY 

Item

Subsystem

Sub-Subsystem

H1 70

2

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:19 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

I1 75

2

J1 80

2

K1 85

2

L1 90

2

M1 99

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value Material Labor Burden End Item 

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

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

M1 99

2

N1 00

2

SU

BS

YS

05 Cylinder Blocks

A1 01

B1 02

C1 03

D1 04

TECHNO

LOGY 

PACKAG

Item

Subsystem

Sub-Subsystem

E1 65

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:20 of 20 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

F1 66

G1 67

H1 70

I1 75

J1 80

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value 

Scaling Factor 

Relative to Base 

(Ford Fusion HEV)

Value Material Labor Burden End Item 

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

Passenger + Midsize Towing Truck 

Segment 

Passenger 5-6

Towing 4000-5000lbs 

(10,000 lb GCWR)

(e.g. Ford Explorer, 3.5L V6)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Large Size Vehicle Segment

Passenger 6-8

(e.g. Ford Flex)

Passenger or Commercial Truck with 

Strong Towing Capabilities

Passenger 3-6

Towing 6000-8000lbs

(15,000 lb GCWR)

(e.g. Ford F150 6.2L V8)

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

J1 80

K1 85

L1 90

M1 99

N1 00

SU

BS

YS

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:1 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

120300 Refrigeration/Air Conditioning Subsystem

1 00 Assembly of Refrigeration/Air Conditioning Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 01 AC Compressor $ 148.86 $ 23.86 $ 43.32 $ 216.04 $ 1.85 $ 14.57 $ 13.38 $ 5.46 $ 35.25 $ - $ 251.30 $ - $ - $ - $ 24.10 $ 19.18 $ 25.92 $ 69.20

3 02 Condenser $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

4 05 AC Lines, Receiver Drier and Accumulator $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

5 10 Plugs $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

System 

ED&T/R&D

(x1000)

Investment

(X1000)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

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

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

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLO

2010 Ford Fusion, 3.0L 

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Technology Level: Power-Split HEV Technology

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

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

6 70 Pipes, Hoses, Ducting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

7 75 Brackets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 97 Vehicle Wiring - Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SUBSYSTEM ROLL-UP $ 148.86 $ 23.86 $ 43.32 $ 216.04 $ 1.85 $ 14.57 $ 13.38 $ 5.46 $ 35.25 $ - $ 251.30 $ - $ - $ - $ 24.10 $ 19.18 $ 25.92 $ 69.20

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:2 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

System 

ED&T/R&D

(x1000)

Investment

(X1000)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

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

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

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLO

2010 Ford Fusion, 3.0L 

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Technology Level: Power-Split HEV Technology

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

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

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:3 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

System 

ED&T/R&D

(x1000)

Investment

(X1000)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

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

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

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLO

2010 Ford Fusion, 3.0L 

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Technology Level: Power-Split HEV Technology

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

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

Material Labor Burden End Item 

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

05 Cylinder Blocks

BASE TECHNOLOGY PACKAGE COST INFORMATION

Item

Subsystem

Sub-Subsystem

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Markup

BASE 

TECHNO

LOGY 

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Total Markup 

Cost 

(Component/ 

Assembly)

Investment

(X1000)

BASE TECHNOLO

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

A1 01 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B1 02 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

C1 03 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

D1 04 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - #REF! #REF! #REF! #REF!

2 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - #REF! #REF! #REF! #REF!

E1 65 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

F1 66 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

G1 67 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

H1 70 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

I1 75 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

J1 80 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

K1 85 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

L1 90 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

M1 99 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

N1 00 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 $ $ - $ $ - $ - $ $ - $ - $ - $ - $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ - $ $ - $ - $ $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:4 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

System 

ED&T/R&D

(x1000)

Investment

(X1000)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

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

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

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLO

2010 Ford Fusion, 3.0L 

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Technology Level: Power-Split HEV Technology

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

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

SU

BS

YS

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - #REF! #REF! #REF! #REF!

Material Labor Burden End Item 

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

Item

Subsystem

Sub-Subsystem

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

TECHNO

LOGY 

PACKAG

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE INCREMENTAL COST TO 

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

05 Cylinder Blocks

A1 01 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B1 02 $ 148.86 $ 23.86 $ 43.32 $ 216.04 $ 1.85 $ 14.57 $ 13.38 $ 5.46 $ 35.25 $ - $ 251.30 $ - $ - $ - $ 24.10 $ 19.18 $ 25.92 $ 69.20

C1 03 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

D1 04 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - #REF! #REF! #REF! #REF!

E1 65 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

F1 66 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

G1 67 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

H1 70 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

I1 75 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

J1 80 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

K1 85 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

L1 90 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

M1 99 $ - $ - $ - $ $ - $ - $ - $ - $ - $ $ - $ - $ $ - $ - $ - $ - $ - $ - $ - $ $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:5 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

System 

ED&T/R&D

(x1000)

Investment

(X1000)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Sub-Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

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

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

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLO

2010 Ford Fusion, 3.0L 

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Technology Level: Power-Split HEV Technology

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

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

N1 00 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SU

BS

YS

#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:6 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

120300 Refrigeration/Air Conditioning Subsystem

1 00

2 01

3 02

4 05

5 10

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

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

$ 0.58 $ 6.52 $ 5.56 $ 1.89 $ 14.56 $ - $ 83.75 $ - $ - $ - $ 124.76 $ 4.68 $ 17.40 $ 146.85 $ 1.27 $ 8.04 $ 7.82 $ 3.57 $ 20.70 $ - $ 167.54 $ - $ -

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

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

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

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:

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

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

6 70

7 75

8 80

9 85

10 97

11 99

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

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

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

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

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

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

$ 0.58 $ 6.52 $ 5.56 $ 1.89 $ 14.56 $ - $ 83.75 $ - $ - $ - ###### $ 4.68 $ 17.40 $ 146.85 $ 1.27 $ 8.04 $ 7.82 $ 3.57 $ 20.70 $ - $ 167.54 $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:7 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

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

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:

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

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:8 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

05 Cylinder Blocks

Item

Subsystem

Sub-Subsystem

BASE 

TECHNO

LOGY 

End Item 

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

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:

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

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

End Item 

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

Investment

(X1000)

System 

ED&T/R&D

(x1000)

BASE TECHNOLOGY PACKAGE COST INFORMATION

Tooling 

(x1000)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

A1 01

2

B1 02

2

C1 03

2

D1 04

2

E1 65

2

F1 66

2

G1 67

2

H1 70

2

I1 75

2

J1 80

2

K1 85

2

L1 90

2

M1 99

2

N1 00

2

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

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

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

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

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

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

#REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ -

#REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ -

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2 $ - $ - $ - $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:9 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

SU

BS

YS

Item

Subsystem

Sub-Subsystem

TECHNO

LOGY 

PACKAG

End Item 

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

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:

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

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

#REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ -

End Item 

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

Tooling 

(x1000)

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Investment

(X1000)

05 Cylinder Blocks

A1 01

B1 02

C1 03

D1 04

E1 65

F1 66

G1 67

H1 70

I1 75

J1 80

K1 85

L1 90

M1 99

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

$ 0.58 $ 6.52 $ 5.56 $ 1.89 $ 14.56 $ - $ 83.75 $ - $ - $ -

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

#REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ -

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

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

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

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

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

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

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

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

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

M1 99 $ - $ - $ - $ - $ $ - $ - $ $ - $ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:10 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

N1 00

SU

BS

YS

End Item 

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

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:

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

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

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

#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:11 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

120300 Refrigeration/Air Conditioning Subsystem

1 00

2 01

3 02

4 05

5 10

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

$ -

$ -

$ -

$ -

$ -

Investment(X1

000)

6 70

7 75

8 80

9 85

10 97

11 99

$ -

$ -

$ -

$ -

$ -

$ -

$ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:12 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

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:13 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

05 Cylinder Blocks

Item

Subsystem

Sub-Subsystem

BASE 

TECHNO

LOGY 

Investment(X1

000)

A1 01 2

B1 02 2

C1 03 2

D1 04 2

E1 65 2

F1 66 2

G1 67 2

H1 70 2

I1 75 2

J1 80 2

K1 85 2

L1 90 2

M1 99 2

N1 00 2

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:14 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

SU

BS

YS

Item

Subsystem

Sub-Subsystem

TECHNO

LOGY 

PACKAG

Investment(X1

000)

05 Cylinder Blocks

A1 01

B1 02

C1 03

D1 04

E1 65

F1 66

G1 67

H1 70

I1 75

J1 80

K1 85

L1 90

M1 99

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:15 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

N1 00

SU

BS

YS

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: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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

120300 Refrigeration/Air Conditioning Subsystem

1 00 Assembly of Refrigeration/Air Conditioning Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A Installation of AC Compressor into vehicle. 12 03 00 - N0502- 01 1 NA 1

Three fasteners used to secure both 

HEV and Baseline compressor into 

vehicle. Both use portion of a 

secondary mounting bracket, 

considered package versus 

performance driven.

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

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

NEW TECHNOLOGY GENERAL PART INFORMATION:

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

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

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem

Technology Level: Power-Split HEV Technology

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

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

performance driven.

2 01 AC Compressor $ 148.86 $ 23.86 $ 43.32 $ 216.04 $ 1.85 $ 14.57 $ 13.38 $ 5.46 $ 35.25 $ - $ 251.30 $ -

A H Electric AC Compressor Assembly 12 03 01 - N0502- 01 1 Full 1

Belt driven AC compressor for 

baseline and HV Electric AC for 

HEV application.

$ 148.86 $ 23.86 $ 43.32 $ 216.04 $ 1.85 $ 14.57 $ 13.38 $ 5.46 $ 35.25 $ - $ 251.30 $ -

3 02 Condenser $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

4 05 AC Lines, Receiver Drier and Accumulator $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

5 10 Plugs $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

6 70 Pipes, Hoses, Ducting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

7 75 Brackets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A H Bracket AC Compressor Mount 12 03 75 - N0502- 01 1 NA 1

Both the base and HEV have AC 

mounting brackets, size and 

complexity driven by packaging 

versus technology adaptation.

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

8 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A H Bolt AC Compressor Bracket 12 03 80 - N0502- 01 2 NA 1

Bolts for AC bracket packaging 

driven versus associated w. 

A H Bolt AC Compressor Bracket 12 03 80 - N0502- 01 2 NA 1 adaptation of mechanical ( i.e. belt) adaptation of mechanical ( i.e. belt) $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

versus electric driven AC 

compressor 

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

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: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

NEW TECHNOLOGY GENERAL PART INFORMATION:

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

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

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem

Technology Level: Power-Split HEV Technology

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

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

B H Bolt AC Compressor 12 03 80 - N0502- 02 3 NA 1

Same number and approx. size to 

mount mechanical and electrical 

compressors.

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

9 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

10 97 Vehicle Wiring - Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A HV Wire Harness - HEV Underbody (14B322) 12 03 97 - N0502- 01 1 NA 1

Wiring and VO connection assembly 

labor captured in Power Distribution 

System as part of HV wire harness.

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

B LV Wire Harness - AC Compressor Control (14290) 12 03 97 - N0502- 02 1 NA 1

For Fusion HEV LV AC Compressor 

Electrical Control Connection (4 Pin 

High Gauge Wire) offset by Field 

Coil Electrical Connection on Base 

Mechanical Connector (2 Pin Low 

Gauge Wire)

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

11 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

$ 148.86 $ 23.86 $ 43.32 $ 216.04 $ 1.85 $ 14.57 $ 13.38 $ 5.46 $ 35.25 $ - $ 251.30 $ -

NOTES:

1.

No Complete Subsystem Quote 

(Yes/No)

 = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

09000064810ec171.xls

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

Author: G. Kolwich

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

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

0 n/a n/a

120300 Refrigeration/Air Conditioning Subsystem

1 00 Assembly of Refrigeration/Air Conditioning Subsystem

A Installation of AC Compressor into vehicle. 12 03 00 - N0502- 01 1 NA 1

Three fasteners used to secure both 

HEV and Baseline compressor into 

vehicle. Both use portion of a 

secondary mounting bracket, 

considered package versus 

performance driven.

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

NEW TECHNOLOGY GENERAL PART INFORMATION:

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

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

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Power-Split HEV Technology

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

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

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

performance driven.

2 01 AC Compressor

A H Electric AC Compressor Assembly 12 03 01 - N0502- 01 1 Full 1

Belt driven AC compressor for 

baseline and HV Electric AC for 

HEV application.

3 02 Condenser

4 05 AC Lines, Receiver Drier and Accumulator

5 10 Plugs

6 70 Pipes, Hoses, Ducting

7 75 Brackets

A H Bracket AC Compressor Mount 12 03 75 - N0502- 01 1 NA 1

Both the base and HEV have AC 

mounting brackets, size and 

complexity driven by packaging 

versus technology adaptation.

8 80 Boltings

A H Bolt AC Compressor Bracket 12 03 80 - N0502- 01 2 NA 1

Bolts for AC bracket packaging 

driven versus associated w. 

adaptation of mechanical ( i.e. belt) 

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

A H Bolt AC Compressor Bracket 12 03 80 - N0502- 01 2 NA 1 adaptation of mechanical ( i.e. belt) $ - $ -

versus electric driven AC 

compressor 

$ - $ -

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: 8/30/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

NEW TECHNOLOGY GENERAL PART INFORMATION:

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

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

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Power-Split HEV Technology

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

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

B H Bolt AC Compressor 12 03 80 - N0502- 02 3 NA 1

Same number and approx. size to 

mount mechanical and electrical 

compressors.

9 85 Sealing Elements

10 97 Vehicle Wiring - Misc

A HV Wire Harness - HEV Underbody (14B322) 12 03 97 - N0502- 01 1 NA 1

Wiring and VO connection assembly 

labor captured in Power Distribution 

System as part of HV wire harness.

Investment

(X1000)

Tooling 

(x1000)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

B LV Wire Harness - AC Compressor Control (14290) 12 03 97 - N0502- 02 1 NA 1

For Fusion HEV LV AC Compressor 

Electrical Control Connection (4 Pin 

High Gauge Wire) offset by Field 

Coil Electrical Connection on Base 

Mechanical Connector (2 Pin Low 

Gauge Wire)

11 99 Miscellaneous

NOTES:

1.

No Complete Subsystem Quote 

(Yes/No)

 = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

$ - $ -

$ - $ -

$ - $ -

$ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:1 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

0 n/a n/a $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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

120300 Refrigeration/Air Conditioning Subsystem

1 00 Assembly of Refrigeration/Air Conditioning Subsystem $ 24.10 $ 19.18 $ 25.92 $ 69.20 $ 0.58 $ 6.52 $ 5.56 $ 1.89 $ 14.56 $ - $ 83.75 $ -

A Installation of AC Compressor into vehicle. 12 03 00 - B0502 - 01 1 NA 1

Three fasteners used to secure both 

HEV and Baseline compressor into 

vehicle. Both use portion of a 

secondary mounting bracket, 

considered package versus 

performance driven.

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

Sub-Subsystem

Part Number

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

System 

ED&T/R&D

(x1000)

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Technology Level: Power-Split HEV Technology

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

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

performance driven.

2 01 AC Compressor $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A G Mechanical AC Compressor Assembly 12 03 01 - B0502 - 01 1 Full 1

Belt driven AC compressor for 

baseline and HV Electric AC for 

HEV application.

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

3 02 Condenser $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

4 05 AC Lines, Receiver Drier and Accumulator $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

5 10 Plugs $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

6 70 Pipes, Hoses, Ducting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

7 75 Brackets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A H Bracket AC Compressor Mount 12 03 75 - B0502 - 01 1 NA 1

Both the base and HEV have AC 

mounting brackets, size and 

complexity driven by packaging 

versus technology adaptation.

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

8 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A H Bolt AC Compressor Bracket 12 03 80 - B0502 - 01 3 NA 1

Bolts for AC bracket packaging 

driven versus associated w. 

A H Bolt AC Compressor Bracket 12 03 80 - B0502 - 01 3 NA 1 adaptation of mechanical ( i.e. belt) adaptation of mechanical ( i.e. belt) $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

versus electric driven AC 

compressor 

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

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: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

Sub-Subsystem

Part Number

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

System 

ED&T/R&D

(x1000)

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Technology Level: Power-Split HEV Technology

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

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

B H Bolt AC Compressor 12 03 80 - B0502 - 02 3 NA 1

Same number and approx. size to 

mount mechanical and electrical 

compressors.

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

9 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

10 97 Vehicle Wiring - Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A Field Coil Electrical Connection 12 03 97 - B0502 - 02 1 NA 1

For Fusion HEV LV AC Compressor 

Electrical Control Connection (4 Pin 

High Gauge Wire) offset by Field 

Coil Electrical Connection on Base 

Mechanical Connector (2 Pin Low 

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

Mechanical Connector (2 Pin Low 

Gauge Wire)

11 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

Complete Subsystem Quote 

(Yes/No) 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: 8/30/2012

DRAFT

0 n/a n/a

120300 Refrigeration/Air Conditioning Subsystem

1 00 Assembly of Refrigeration/Air Conditioning Subsystem

A Installation of AC Compressor into vehicle. 12 03 00 - B0502 - 01 1 NA 1

Three fasteners used to secure both 

HEV and Baseline compressor into 

vehicle. Both use portion of a 

secondary mounting bracket, 

considered package versus 

performance driven.

Sub-Subsystem

Part Number

QTY/ Subsystem

Notes

Subassembly

Component

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Power-Split HEV Technology

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

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

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

performance driven.

2 01 AC Compressor

A G Mechanical AC Compressor Assembly 12 03 01 - B0502 - 01 1 Full 1

Belt driven AC compressor for 

baseline and HV Electric AC for 

HEV application.

3 02 Condenser

4 05 AC Lines, Receiver Drier and Accumulator

5 10 Plugs

6 70 Pipes, Hoses, Ducting

7 75 Brackets

A H Bracket AC Compressor Mount 12 03 75 - B0502 - 01 1 NA 1

Both the base and HEV have AC 

mounting brackets, size and 

complexity driven by packaging 

versus technology adaptation.

8 80 Boltings

A H Bolt AC Compressor Bracket 12 03 80 - B0502 - 01 3 NA 1

Bolts for AC bracket packaging 

driven versus associated w. 

adaptation of mechanical ( i.e. belt) 

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

A H Bolt AC Compressor Bracket 12 03 80 - B0502 - 01 3 NA 1 adaptation of mechanical ( i.e. belt) $ - $ -

versus electric driven AC 

compressor 

$ - $ -

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: 8/30/2012

DRAFT

Sub-Subsystem

Part Number

QTY/ Subsystem

Notes

Subassembly

Component

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Power-Split HEV Technology

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

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

B H Bolt AC Compressor 12 03 80 - B0502 - 02 3 NA 1

Same number and approx. size to 

mount mechanical and electrical 

compressors.

9 85 Sealing Elements

10 97 Vehicle Wiring - Misc

A Field Coil Electrical Connection 12 03 97 - B0502 - 02 1 NA 1

For Fusion HEV LV AC Compressor 

Electrical Control Connection (4 Pin 

High Gauge Wire) offset by Field 

Coil Electrical Connection on Base 

Mechanical Connector (2 Pin Low 

Investment

(X1000)

Tooling 

(x1000)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

Mechanical Connector (2 Pin Low 

Gauge Wire)

11 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: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

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

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

120300 Refrigeration/Air Conditioning Subsystem

1 00 Assembly of Refrigeration/Air Conditioning Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

2 01 AC Compressor $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

3 02 Condenser $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

Sub-Subsystem

Part Number

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

System 

ED&T/R&D

(x1000)

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Technology Level: Power-Split HEV Technology

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

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

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

4 05 AC Lines, Receiver Drier and Accumulator $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

5 10 Plugs $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

6 70 Pipes, Hoses, Ducting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

7 75 Brackets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

8 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

9 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

10 97 Vehicle Wiring - Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

11 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - Complete Subsystem Quote 

(Yes/No)

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: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

Sub-Subsystem

Part Number

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

System 

ED&T/R&D

(x1000)

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Technology Level: Power-Split HEV Technology

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

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

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

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: 8/30/2012

DRAFT

0

120300 Refrigeration/Air Conditioning Subsystem

1 00 Assembly of Refrigeration/Air Conditioning Subsystem

2 01 AC Compressor

3 02 Condenser

Sub-Subsystem

Part Number

QTY/ Subsystem

Notes

Subassembly

Component

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Power-Split HEV Technology

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

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

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

4 05 AC Lines, Receiver Drier and Accumulator

5 10 Plugs

6 70 Pipes, Hoses, Ducting

7 75 Brackets

8 80 Boltings

9 85 Sealing Elements

10 97 Vehicle Wiring - Misc

11 99 Miscellaneous

Complete Subsystem Quote 

(Yes/No)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

(Yes/No)

09000064810ec171.xls

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

Author: G. Kolwich

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

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Sub-Subsystem

Part Number

QTY/ Subsystem

Notes

Subassembly

Component

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Power-Split HEV Technology

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

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

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

Investment

(X1000)

Tooling 

(x1000)

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:1 of 4 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

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

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

120301 Refrigeration/Air Conditioning Subsystem - AC Compressor

1 Castings 120301-N0602-100 thru -120 $ 9.92 $ 9.47 $ 17.15 $ 36.54 $ 0.92 $ 2.42 $ 2.24 $ 0.93 $ 6.51 $ - $ 43.05

1 H Impeller Scroll Asm, Scroll # 03 01 - N0602- 100 1 Full 1 Cost roll-up in single MAQS $ - $ -

2 H Scroll Housing # 03 01 - N0602- 105 1 Full 1 Cost roll-up in single MAQS

3 H Rear Scroll # 03 01 - N0602- 110 1 Full 1 Cost roll-up in single MAQS

4 H Midplate # 03 01 - N0602- 115 1 Full 1 Cost roll-up in single MAQS

5 H Housing, Compressor Motor # 03 01 - N0602- 120 1 Full 1 Cost roll-up in single MAQS

Subassembly

Component

Sub-Subsystem

NEW TECHNOLOGY GENERAL PART INFORMATION:

Electric Air Conditioning Compressor: AC Synchronous, Permanent 

Magnet, 3 Phase, 6 Pole Motor

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Assembly

Name/Description Part Number

Total 

Packaging 

Cost 

(Component

/ Assembly)

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: N0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

2 Motor Rotor Assembly 120301-N0602-500 thru -525 $ 10.30 $ 2.89 $ 6.47 $ 19.66 $ 0.10 $ 1.28 $ 1.18 $ 0.49 $ 3.05 $ - $ 22.71

1 Motor Rotor Assembly # 03 01 - N0602- 525 1 Full 1 $ 10.30 $ 2.89 $ 6.47 $ 19.66 $ 0.10 $ 1.28 $ 1.18 $ 0.49 $ 3.05 $ - $ 22.71

3 Motor Stator Assembly 120301-N0602-550 thru -575 $ 11.61 $ 2.26 $ 3.81 $ 17.67 $ 0.09 $ 1.15 $ 1.06 $ 0.44 $ 2.74 $ - $ 20.41

1 Motor Stator Assembly # 03 01 - N0602- 575 1 Full 1 $ 11.61 $ 2.26 $ 3.81 $ 17.67 $ 0.09 $ 1.15 $ 1.06 $ 0.44 $ 2.74 $ - $ 20.41

4 Electonic Assemblies and Components 120301-N0602-299 Thru -435 $ 104.49 $ 3.74 $ 4.82 $ 113.05 $ 0.57 $ 7.35 $ 6.78 $ 2.83 $ 17.52 $ - $ 130.58

1 Electronic Board #1 # 03 01 - N0602- 398 1 Full 1 $ 40.41 $ 0.69 $ 1.77 $ 42.86 $ 0.21 $ 2.79 $ 2.57 $ 1.07 $ 6.64 $ - $ 49.51

2 Electronic Board #2 # 03 01 - N0602- 299 1 Full 1 $ 48.99 $ 1.32 $ 2.35 $ 52.66 $ 0.26 $ 3.42 $ 3.16 $ 1.32 $ 8.16 $ - $ 60.83

3 Electronics, Misc # 03 01 - N0602- Var 1 Full 1 $ 6.00 $ 0.02 $ 0.04 $ 6.05 $ 0.03 $ 0.39 $ 0.36 $ 0.15 $ 0.94 $ - $ 6.99

4 Main High Voltage Harness # 03 01 - N0602- 475 1 Full 1 $ 9.10 $ 1.71 $ 0.67 $ 11.48 $ 0.06 $ 0.75 $ 0.69 $ 0.29 $ 1.78 $ - $ 13.26

5 Misc Components 120301-N0602-900 Thru -909 $ 2.66 $ 2.22 $ 4.06 $ 8.95 $ 0.07 $ 1.06 $ 0.91 $ 0.27 $ 2.31 $ - $ 11.26

(Includes misc. pins, shafts, seals, stampings, etc) # 03 01 - N0602- Var 1 Full 1 $ 2.66 $ 2.22 $ 4.06 $ 8.95 $ 0.07 $ 1.06 $ 0.91 $ 0.27 $ 2.31 $ - $ 11.26

6 T1 Assembly and Misc Purcahsed Parts, 120301-N0602-001 thru -100 $ 9.88 $ 3.28 $ 7.01 $ 20.17 $ 0.10 $ 1.31 $ 1.21 $ 0.50 $ 3.13 $ - $ 23.30

Compressor Assembly - Air Conditioning # 03 01 - N0602- 035 $ 9.88 $ 3.28 $ 7.01 $ 20.17 $ 0.10 $ 1.31 $ 1.21 $ 0.50 $ 3.13 $ - $ 23.30

$ 148.86 $ 23.86 $ 43.32 $ 216.04 $ 1.85 $ 14.57 $ 13.38 $ 5.46 $ 35.25 $ - $ 251.30

NOTES:

(Includes core plates, magnets, end caps, weights, rivets, 

shaft, etc)

(Includes core plates, windings, end caps, terminals, etc)

Yes Complete Subsystem Quote 

(Yes/No)

NOTES:

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: 8/30/2012

DRAFT

Material Labor Burden End Item 

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

Subassembly

Component

Sub-Subsystem

NEW TECHNOLOGY GENERAL PART INFORMATION:

Electric Air Conditioning Compressor: AC Synchronous, Permanent 

Magnet, 3 Phase, 6 Pole Motor

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Assembly

Name/Description Part Number

Total 

Packaging 

Cost 

(Component

/ Assembly)

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: N0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

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: 8/30/2012

DRAFT

0

120301 Refrigeration/Air Conditioning Subsystem - AC Compressor

1 Castings 120301-N0602-100 thru -120

1 H Impeller Scroll Asm, Scroll # 03 01 - N0602- 100 1 Full 1 Cost roll-up in single MAQS

2 H Scroll Housing # 03 01 - N0602- 105 1 Full 1 Cost roll-up in single MAQS

3 H Rear Scroll # 03 01 - N0602- 110 1 Full 1 Cost roll-up in single MAQS

4 H Midplate # 03 01 - N0602- 115 1 Full 1 Cost roll-up in single MAQS

5 H Housing, Compressor Motor # 03 01 - N0602- 120 1 Full 1 Cost roll-up in single MAQS

Subassembly

Component

Sub-Subsystem

NEW TECHNOLOGY GENERAL PART INFORMATION:

Electric Air Conditioning Compressor: AC Synchronous, Permanent 

Magnet, 3 Phase, 6 Pole Motor

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: N0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

Tooling 

(x1000)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

2 Motor Rotor Assembly 120301-N0602-500 thru -525

1 Motor Rotor Assembly # 03 01 - N0602- 525 1 Full 1

3 Motor Stator Assembly 120301-N0602-550 thru -575

1 Motor Stator Assembly # 03 01 - N0602- 575 1 Full 1

4 Electonic Assemblies and Components 120301-N0602-299 Thru -435

1 Electronic Board #1 # 03 01 - N0602- 398 1 Full 1

2 Electronic Board #2 # 03 01 - N0602- 299 1 Full 1

3 Electronics, Misc # 03 01 - N0602- Var 1 Full 1

4 Main High Voltage Harness # 03 01 - N0602- 475 1 Full 1

5 Misc Components 120301-N0602-900 Thru -909

(Includes misc. pins, shafts, seals, stampings, etc) # 03 01 - N0602- Var 1 Full 1

6 T1 Assembly and Misc Purcahsed Parts, 120301-N0602-001 thru -100 

Compressor Assembly - Air Conditioning # 03 01 - N0602- 035

NOTES:

(Includes core plates, magnets, end caps, weights, rivets, 

shaft, etc)

(Includes core plates, windings, end caps, terminals, etc)

Yes Complete Subsystem Quote 

(Yes/No)

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

$ - $ - $ -

NOTES:

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: 8/30/2012

DRAFT

Subassembly

Component

Sub-Subsystem

NEW TECHNOLOGY GENERAL PART INFORMATION:

Electric Air Conditioning Compressor: AC Synchronous, Permanent 

Magnet, 3 Phase, 6 Pole Motor

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Electrically Versus Mechanically Driven Air Conditioning Compressor

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

Study Case#: N0602 (N=New, B=Base, ) 06=Technology Package, 02=Vehicle Class

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

Tooling 

(x1000)

Investment

(X1000)

System 

ED&T/R&D

(x1000)

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 4 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-100/120 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

1 1A H Impeller Scroll Asm, Scroll 120301-N0602-100-5 1 Cast & Trim T1 Assembly, Mark-up Applied 

@ Bottom. Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, SMS 514 1 1 1.1 0.617 $1.10 $41.48 $116.73 $128.40 $0.68 $0.08 $0.25 $1.01 5.00% 0.00% 0.00% 0.00% 5.00% $0.05 $1.06 $1.06 $0.68

2 1B H Impeller Scroll Asm, Scroll 120301-N0602-100-4 1 Stress Relief Heat Treat T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Heat Treat Operator T5-Al380, SMS 387 1.5 1 1 0.617 $0.01 $47.72 $10.17 $10.17 $0.01 $0.19 $0.03 $0.22 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.22 $0.22 $0.01

3 1C H Impeller Scroll Asm, Scroll 120301-N0602-100-3 1 Machine T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable CNC Operator CNC Machining, LC, Automatic Load124 2 4 1 0.000 $0.00 $36.98 $40.26 $161.04 $0.00 $0.60 $1.30 $1.89 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.89 $1.89 $0.00

T1 Assembly, Mark-up Applied 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

4 1D H Impeller Scroll Asm, Scroll 120301-N0602-100-2 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LC 277 1 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.14 $0.04 $0.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.18 $0.18 $0.00

5 1E H Impeller Scroll Asm, Scroll 120301-N0602-100-1 1 Anodize T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Plating/Coating Operator Anodize, SMS, MHC 300 2 1 1 0.000 $0.00 $40.84 $150.00 $150.00 $0.00 $0.27 $0.50 $0.77 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.77 $0.77 $0.00

6

7 2A H Scroll Housing 120301-N0602-105-4 1 Cast & Trim T1 Assembly, Mark-up Applied 

@ Bottom. Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, MS 324 1 1 1.1 2.158 $1.10 $41.48 $197.05 $216.76 $2.37 $0.13 $0.67 $3.17 5.00% 0.00% 0.00% 0.00% 5.00% $0.16 $3.33 $3.33 $2.37

8 2B H Scroll Housing 120301-N0602-105-3 1 Stress Relief Heat Treat T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Heat Treat Operator T5-Al380, SMS 292 3 4 1 2.158 $0.01 $47.72 $10.17 $40.68 $0.03 $0.49 $0.14 $0.66 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.66 $0.66 $0.03

9 2C H Scroll Housing 120301-N0602-105-2 1 Machine T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable CNC Operator CNC Machining, LC, Automatic Load107 3 6 1 0.000 $0.00 $36.98 $40.26 $241.56 $0.00 $1.04 $2.26 $3.30 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $3.30 $3.30 $0.00

10 2D H Scroll Housing 120301-N0602-105-1 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LC 277 1 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.14 $0.04 $0.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.18 $0.18 $0.00

11

12 3A H Rear Scroll 120301-N0602-110-5 1 Cast & Trim T1 Assembly, Mark-up Applied 

@ Bottom. Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, SMS 456 1 1 1.1 0.768 $1.10 $41.48 $116.73 $128.40 $0.84 $0.09 $0.28 $1.22 5.00% 0.00% 0.00% 0.00% 5.00% $0.06 $1.28 $1.28 $0.84

13 3B H Rear Scroll 120301-N0602-110-4 1 Stress Relief Heat Treat T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Heat Treat Operator T5-Al380, SMS 387 1.5 1 1 0.768 $0.01 $47.72 $10.17 $10.17 $0.01 $0.19 $0.03 $0.22 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.22 $0.22 $0.01

14 3C H Rear Scroll 120301-N0602-110-3 1 Machine T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable CNC Operator CNC Machining, LC, Automatic Load118 3 6 1 0.000 $0.00 $36.98 $40.26 $241.56 $0.00 $0.94 $2.04 $2.98 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.98 $2.98 $0.00

15 3D H Rear Scroll 120301-N0602-110-2 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LC 277 1 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.14 $0.04 $0.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.18 $0.18 $0.00

16 3E H Rear Scroll 120301-N0602-110-1 1 Anodize T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Plating/Coating Operator Anodize, SMS, MHC 300 2 1 1 0.000 $0.00 $40.84 $150.00 $150.00 $0.00 $0.27 $0.50 $0.77 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.77 $0.77 $0.00

17

18 4A H Midplate 120301-N0602-115-4 1 Cast & Trim T1 Assembly, Mark-up Applied 

@ Bottom. Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, SMS 340 1 1 1.1 0.784 $1.10 $41.48 $116.73 $128.40 $0.86 $0.12 $0.38 $1.36 5.00% 0.00% 0.00% 0.00% 5.00% $0.07 $1.43 $1.43 $0.86

19 4B H Midplate 120301-N0602-115-3 1 Stress Relief Heat Treat T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Heat Treat Operator T5-Al380, SMS 265 1.5 1 1 0.784 $0.01 $47.72 $10.17 $10.17 $0.01 $0.27 $0.04 $0.32 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.32 $0.32 $0.01

20 4C H Midplate 120301-N0602-115-2 1 Machine T1 Assembly, Mark-up Applied 20 4C H Midplate 120301-N0602-115-2 1 Machine Not Applicable CNC Operator CNC Machining, LC, Automatic Load141 2 4 1 0.000 $0.00 $36.98 $40.26 $161.04 $0.00 $0.52 $1.14 $1.66 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.66 $1.66 $0.00 T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable CNC Operator CNC Machining, LC, Automatic Load141 2 4 1 0.000 $0.00 $36.98 $40.26 $161.04 $0.00 $0.52 $1.14 $1.66 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.66 $1.66 $0.00

21 4D H Midplate 120301-N0602-115-1 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LC 257 1 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.15 $0.04 $0.19 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.19 $0.19 $0.00

22

23 5A H Housing, Compressor Motor 120301-N0602-120-4 1 Cast & Trim T1 Assembly, Mark-up Applied 

@ Bottom. Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, MS 181 2 2 1.1 4.594 $1.10 $41.48 $197.05 $433.51 $5.05 $0.46 $2.40 $7.91 5.00% 0.00% 0.00% 0.00% 5.00% $0.40 $8.30 $8.30 $5.05

24 5B H Housing, Compressor Motor 120301-N0602-120-3 1 Stress Relief Heat Treat T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Heat Treat Operator T5-Al380, SMS 176 3 6 1 4.594 $0.01 $47.72 $10.17 $61.02 $0.06 $0.81 $0.35 $1.22 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.22 $1.22 $0.06

25 5C H Housing, Compressor Motor 120301-N0602-120-2 1 Machine T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable CNC Operator CNC Machining, LC, Automatic Load105 6 12 1 0.000 $0.00 $36.98 $40.26 $483.12 $0.00 $2.12 $4.61 $6.72 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $6.72 $6.72 $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 4 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-100/120 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

26 5D H Housing, Compressor Motor 120301-N0602-120-1 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Washing Equipment, LMC 240 2 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.32 $0.09 $0.41 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.41 $0.41 $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

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

Material

$9.92

Material Labor Burden TMC Scrap SG&A Profit ED&T Total Material Labor Burden TMC Scrap SG&A Profit ED&T 1 $37.27 Total 

Mark-up $37.27

T1 or OEM Total Manufacturing Cost: $9.92 $9.47 $17.15 $36.54 $0.73 $0.00 $0.00 $0.00 $0.73 $37.27

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 ----- ----- ----- $0.19 $2.42 $2.24 $0.93 $5.78

Base Cost Impact to Vehicle: $9.92 $9.47 $17.15 $36.54 $0.92 $2.42 $2.24 $0.93 $6.51 $43.05 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $43.05

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 Cost Total: $0.000

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

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

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

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

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 4 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

Purchase Part - High Impact Item (Full Cost Mapping)

1A H Impeller Scroll Asm, Scroll 120301-N0602-100-5

1B H Impeller Scroll Asm, Scroll 120301-N0602-100-4

1C H Impeller Scroll Asm, Scroll 120301-N0602-100-3

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

$0.08 $0.25 $1.01 $0.05 $0.00 $0.00 $0.00 $0.05 4 Cavity Diecast Tool with Operator Manual Load/Unload Trim Station 1.5 2 10 30 47 1410 319 11.28 85% 375 9.59 28 2 4 28 1.1 1.0 514 7.00 1.00

$0.19 $0.03 $0.22 $0.00 $0.00 $0.00 $0.00 $0.00 Batch T5 Process, Manual Load, Heat Treat, Controlled Air Cool 1.5 2 10 30 47 1410 319 11.28 85% 375 9.59 - 3 2,900 27,000 1.0 1.0 387 9.31 1.50

$0.60 $1.30 $1.89 $0.00 $0.00 $0.00 $0.00 $0.00 4 CNC workstations, 2 operators/2 work stations, semi-automated load, auto clamping 5 2 10 100 47 4700 96 37.60 85% 113 31.96 110 1 1 116 1.0 4.0 124 29.00 2.00

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

1D H Impeller Scroll Asm, Scroll 120301-N0602-100-2

1E H Impeller Scroll Asm, Scroll 120301-N0602-100-1

2A H Scroll Housing 120301-N0602-105-4

2B H Scroll Housing 120301-N0602-105-3

2C H Scroll Housing 120301-N0602-105-2

2D H Scroll Housing 120301-N0602-105-1

3A H Rear Scroll 120301-N0602-110-5

3B H Rear Scroll 120301-N0602-110-4

3C H Rear Scroll 120301-N0602-110-3

3D H Rear Scroll 120301-N0602-110-2

3E H Rear Scroll 120301-N0602-110-1

4A H Midplate 120301-N0602-115-4

4B H Midplate 120301-N0602-115-3

4C H Midplate 120301-N0602-115-2

$0.14 $0.04 $0.18 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Wash, Operator Load/Unload (time est. shown for single part) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0 277 13.00 1.00

$0.27 $0.50 $0.77 $0.00 $0.00 $0.00 $0.00 $0.00 Automated Load-Unload 8 Station, Linear\ Anodizing System 2 2 10 40 47 1880 239 15.04 85% 282 12.78 48 8 1 12 1.0 1.0 300 12.00 2.00

$0.13 $0.67 $3.17 $0.16 $0.00 $0.00 $0.00 $0.16 4 Cavity Diecast Tool with Operator Manual Load/Unload Trim Station 2 2 10 40 47 1880 239 15.04 85% 282 12.78 44.4 2 4 44.4 1.1 1.0 324 11.10 1.00

$0.49 $0.14 $0.66 $0.00 $0.00 $0.00 $0.00 $0.00 Batch T5 Process, Manual Load, Heat Treat, Controlled Air Cool 1.5 2 10 30 47 1410 319 11.28 85% 375 9.59 - 3 547 27,000.0 1.0 4.0 292 12.34 3.00

$1.04 $2.26 $3.30 $0.00 $0.00 $0.00 $0.00 $0.00 6, 4 Axis CNC workstations, 3 operators/2 work stations, operator load/unload, auto clamping 5 2 10 100 47 4700 96 37.60 85% 113 31.96 196 1 1 202 1.0 6.0 107 33.67 3.00

$0.14 $0.04 $0.18 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Wash, Operator Load/Unload (time est. shown for single part) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0 277 13.00 1.00

$0.09 $0.28 $1.22 $0.06 $0.00 $0.00 $0.00 $0.06 4 Cavity Diecast Tool with Operator Manual Load/Unload Trim Station 1.5 2 10 30 47 1410 319 11.28 85% 375 9.59 31.6 2 4 31.6 1.1 1.0 456 7.90 1.00

$0.19 $0.03 $0.22 $0.00 $0.00 $0.00 $0.00 $0.00 Batch T5 Process, Manual Load, Heat Treat, Controlled Air Cool 1.5 2 10 30 47 1410 319 11.28 85% 375 9.59 - 3 2,900 27,000.0 1.0 1.0 387 9.31 1.50

$0.94 $2.04 $2.98 $0.00 $0.00 $0.00 $0.00 $0.00 6 CNC workstations, 3 operators/2 work stations, semi-automated load, auto clamping 5 2 10 100 47 4700 96 37.60 85% 113 31.96 177 1 1 183 1.0 6.0 118 30.47 3.00

$0.14 $0.04 $0.18 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Wash, Operator Load/Unload (time est. shown for single part) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0 277 13.00 1.00

$0.27 $0.50 $0.77 $0.00 $0.00 $0.00 $0.00 $0.00 Automated Load-Unload 8 Station, Linear\ Anodizing System 2 2 10 40 47 1880 239 15.04 85% 282 12.78 - 8 1 12 1.0 1.0 300 12.00 2.00

$0.12 $0.38 $1.36 $0.07 $0.00 $0.00 $0.00 $0.07 4 Cavity Diecast Tool with Operator Manual Load/Unload Trim Station 2 2 10 40 47 1880 239 15.04 85% 282 12.78 42.4 2 4 42.4 1.1 1.0 340 10.60 1.00

$0.27 $0.04 $0.32 $0.00 $0.00 $0.00 $0.00 $0.00 Batch T5 Process, Manual Load, Heat Treat, Controlled Air Cool 2.5 2 10 50 47 2350 191 18.80 85% 225 15.98 - 3 1,990 27,000.0 1.0 1.0 265 13.57 1.50

4C H Midplate 120301-N0602-115-2 $0.52 $1.14 $1.66 $0.00 $0.00 $0.00 $0.00 $0.00 4 CNC workstations, 2 operators/2 work stations, semi-automated load, auto clamping 5 2 10 100 47 4700 96 37.60 85% 113 31.96 96.0 1 1 102.0 1.0 4.0 141 25.50 2.00

4D H Midplate 120301-N0602-115-1

5A H Housing, Compressor Motor 120301-N0602-120-4

5B H Housing, Compressor Motor 120301-N0602-120-3

5C H Housing, Compressor Motor 120301-N0602-120-2

$0.52 $1.14 $1.66 $0.00 $0.00 $0.00 $0.00 $0.00 4 CNC workstations, 2 operators/2 work stations, semi-automated load, auto clamping 5 2 10 100 47 4700 96 37.60 85% 113 31.96 96.0 1 1 102.0 1.0 4.0 141 25.50 2.00

$0.15 $0.04 $0.19 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Wash, Operator Load/Unload (time est. shown for single part) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 14 1 1 14 1.0 1.0 257 14.00 1.00

$0.46 $2.40 $7.91 $0.40 $0.00 $0.00 $0.00 $0.40 Single Cavity Diecast Tool with Operator Manual Load/Unload Trim Station, 2 Lines required to meet 

capacity 3.5 2 10 70 47 3290 137 26.32 85% 161 22.37 39.8 2 1 39.8 1.1 2.0 181 19.90 2.00

$0.81 $0.35 $1.22 $0.00 $0.00 $0.00 $0.00 $0.00 Batch T5 Process, Manual Load, Heat Treat, Controlled Air Cool 3.5 2 10 70 47 3290 137 26.32 85% 161 22.37 - 3 220 27,000.0 1.0 6.0 176 20.45 3.00

$2.12 $4.61 $6.72 $0.00 $0.00 $0.00 $0.00 $0.00 6, 4 Axis CNC workstations, 3 operators/2 work stations, operator load/unload, auto clamping 5 2 10 100 47 4700 96 37.60 85% 113 31.96 412 1 1 412 1.0 12.0 105 34.33 6.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 4 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

5D H Housing, Compressor Motor 120301-N0602-120-1

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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

$0.32 $0.09 $0.41 $0.00 $0.00 $0.00 $0.00 $0.00 Conveyor Wash, Operator Load/Unload (time est. shown for single part) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 15 1.0 1.0 240 15.00 2.00

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

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

Total

$9.47 $17.15 $36.54 $0.73 $0.00 $0.00 $0.00 $0.73

$37.27

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: 1 of 4 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-525 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

1 1A H AC Motor Magnets and Shaft Asm. 120301-N0602-525-1 1

Assemble end plates, balancing 

weights and shaft to rotor stack 

subassembly

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Electromechanical Assembly Elec. Assembly, MC, Base 240 4 1 8 0.000 $0.00 $36.21 $30.00 $240.00 $0.00 $0.60 $1.00 $1.60 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.60 $1.60 $0.00

2 1A H AC Motor Magnets and Shaft Asm. 120301-N0602-525 1 Balance Rotor Shaft Assembly T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Electromechanical Assembly Dynamic Balancing, SS, LAV 120 1 2 1 0.000 $0.00 $36.21 $41.86 $83.72 $0.00 $0.30 $0.70 $1.00 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.00 $1.00 $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

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

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

Purchase Part - High Impact Item (Full Cost Mapping)

1 1A H AC Motor Shaft 120301-N0602-500-03 1 Machine T1 Assembly, Mark-up Applied 

@ Bottom. A-Steel-4140, Bar 0.25-1" CNC Operator DS-CNC Turning, SS, BF, QA 119 3 7 1 2.530 $1.23 $36.98 $37.93 $265.51 $3.11 $0.93 $2.22 $6.26 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $6.26 $6.26 $3.11

2 1B H AC Motor Shaft 120301-N0602-500-02 1 Washed T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable CNC Operator Washing Equipment, LC 257 0 1 1 0.000 $0.00 $36.98 $10.75 $10.75 $0.00 $0.00 $0.04 $0.04 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.04 $0.04 $0.00

3 1C H AC Motor Shaft 120301-N0602-500-01 1 Case Harden T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Heat Treat Operator Nitriding - Case Harden 141 1 1 1 0.000 $0.00 $47.72 $100.00 $100.00 $0.00 $0.34 $0.71 $1.05 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.05 $1.05 $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 2A H AC Motor Weight #1 120301-N0602-501 1 Die Cast T1 Assembly, Mark-up Applied 

@ Bottom. Si-Brass-87500, Bar Mold/Cast/Sinter Operator Diecast, SMS 2000 2 1 1.434 0.116 $2.11 $41.48 $116.73 $167.34 $0.24 $0.04 $0.08 $0.37 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.37 $0.37 $0.24

6 3A H AC Motor Weight #1 120301-N0602-502 1 Die Cast T1 Assembly, Mark-up Applied 

@ Bottom. Si-Brass-87500, Bar Mold/Cast/Sinter Operator Diecast, SMS 2000 2 1 1.434 0.074 $2.11 $41.48 $116.73 $167.34 $0.16 $0.04 $0.08 $0.28 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.28 $0.28 $0.16

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 4A H AC Motor Rotor Endplate #1 (Same for #2) 120301-N0602-503/504 2 Stamping T1 Assembly, Mark-up Applied 

@ Bottom. S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, XSS 6000 0.25 1 1.1 0.038 $1.64 $42.73 $24.60 $27.06 $0.06 $0.00 $0.00 $0.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.07 $0.14 $0.12

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 5A H AC Motor 120301-N0602-505 178 Stamping T1 Assembly, Mark-up Applied 

@ Bottom. Si. Elect. Steel Cut/Punch/Forming Operator Stamp/Form, XSS 24000 2 4 1 0.018 $0.75 $42.73 $24.60 $98.40 $0.01 $0.00 $0.00 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.02 $3.77 $2.40

11 5B H AC Motor 120301-N0602-505 1 Rotor Stacking T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Elec. Assembly, MC, Base 135 0 4 1 0.000 $0.00 $42.73 $30.00 $120.00 $0.00 $0.00 $0.89 $0.89 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.89 $0.89 $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

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 1A H AC Motor Rivets 120301-N0602-510 4 S $0.00 $0.09 $0.00 $0.36 $0.36

3 2A H AC Motor Magnets 120301-N0602-511 6

Neodymium Iron Boron 

(NdFeB) S $0.00 $0.65 $0.00 $3.90 $3.90

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

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

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

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 4 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

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

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

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

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

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

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

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

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.

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 4 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-525 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

Material

$10.30

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

Mark-up $19.66

T1 or OEM Total Manufacturing Cost: $10.30 $2.89 $6.47 $19.66 $0.00 $0.00 $0.00 $0.00 $0.00 $19.66

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

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.10 $1.28 $1.18 $0.49 $3.05

Base Cost Impact to Vehicle: $10.30 $2.89 $6.47 $19.66 $0.10 $1.28 $1.18 $0.49 $3.05 $22.71 $0 $0

Packaging Cost: $0.00

3

1

Notes: 

a) Items 1,2, & 3 must a

Net Cost Impact to Vehicle: $22.71

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 Cost Total: $0.000

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

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

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

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

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 4 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

1A H AC Motor Magnets and Shaft Asm. 120301-N0602-525-1

1A H AC Motor Magnets and Shaft Asm. 120301-N0602-525

Purchase Part - High Impact Item (Full Cost Mapping)

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

$0.60 $1.00 $1.60 $0.00 $0.00 $0.00 $0.00 $0.00

Semi automated assembly line Station #1, Manual Assembly End Cap #1, Weight #1, x2 Rivets, 

Automated press of rivets, Station #2 manual reorientate part, install 6 magnets, S#3, manual install end 

cap #2, weight #2, and x2 rivets, auto press rivets home, S#4 auto orbital spin # 1 rivets, S#5 auto 

reorientate assembly, S#6 auto orbital spin #2 rivets. S#7 auto load and press armature shaft, S#8 

operator unload and transfer to balancing line.

5 2 10 100 47 4700 96 37.60 85% 113 31.96 58 8 1 15 8.0 1.0 240 15.00 4.00

$0.30 $0.70 $1.00 $0.00 $0.00 $0.00 $0.00 $0.00 Automatic load/unload, balancing station, Operator oversees 2 stations. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 60 1.0 2.0 120 30.00 1.00

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

1A H AC Motor Shaft 120301-N0602-500-03

1B H AC Motor Shaft 120301-N0602-500-02

1C H AC Motor Shaft 120301-N0602-500-01

2A H AC Motor Weight #1 120301-N0602-501

3A H AC Motor Weight #1 120301-N0602-502

4A H AC Motor Rotor Endplate #1 (Same for #2) 120301-N0602-503/504

5A H AC Motor 120301-N0602-505

5B H AC Motor 120301-N0602-505

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

1A H AC Motor Rivets 120301-N0602-510

2A H AC Motor Magnets 120301-N0602-511

$0.93 $2.22 $6.26 $0.00 $0.00 $0.00 $0.00 $0.00 CNC turn and finish grind, double sided part, 5 2 10 100 47 4700 96 37.60 85% 113 31.96 211 1 1 211 1.0 7.0 119 30.14 3.00

$0.00 $0.04 $0.04 $0.00 $0.00 $0.00 $0.00 $0.00 Batch wash 5 2 10 100 47 4700 96 37.60 85% 113 31.96 14 1 1 14 1.0 1.0 257 14.00 -

$0.34 $0.71 $1.05 $0.00 $0.00 $0.00 $0.00 $0.00 Nitride 24 Hours @ Approx 600°C, Batches of 13500 Parts 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 3,375 86,400 1.0 1.0 141 25.60 1.00

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

$0.04 $0.08 $0.37 $0.00 $0.00 $0.00 $0.00 $0.00 Die Cast 24 Cavity, trim and deflash 0.5 2 10 10 47 470 957 3.76 85% 1126 3.20 1.8 2 24 43 1.4 1.0 2000 1.80 2.00

$0.04 $0.08 $0.28 $0.00 $0.00 $0.00 $0.00 $0.00 Die Cast 24 Cavity, trim and deflash 0.5 2 10 10 47 470 957 3.76 85% 1126 3.20 1.8 2 24 43 1.4 1.0 2000 1.80 2.00

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

$0.00 $0.01 $0.14 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive stamping die and batch wash 1 2 10 20 47 940 957 3.76 85% 1126 3.20 0.6 2 1 0.6 1.1 1.0 6000 0.60 0.25

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

$0.63 $0.73 $3.77 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive stamping die in-line with automatic rotor disc stacking equipment. 5 2 10 100 47 4700 17043 0.21 85% 20050 0.18 0.6 2 1 0.6 1.0 4.0 24000 0.15 2.00

$0.00 $0.89 $0.89 $0.00 $0.00 $0.00 $0.00 $0.00 Rotor stacking equipment, direct feed from stamping press, orientate, stack and press into place 5 2 10 100 47 4700 96 37.60 85% 113 31.96 465 1 1 106.8 1.0 4.0 135 26.70 -

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

$0.36

$3.90

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 4 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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

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

Total

$2.89 $6.47 $19.66 $0.00 $0.00 $0.00 $0.00 $0.00

$19.66

2

Notes: 

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-575 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

1 1A H AC Compressor Motor Stator Assembly 120301-N0602-575-3 1 Install Stator Liners T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Electromechanical Assembly Elec. Assembly, MC, Base 200 0.5 1 1.5 0.000 $0.00 $36.21 $30.00 $45.00 $0.00 $0.09 $0.23 $0.32 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.32 $0.32 $0.00

2 1B H AC Compressor Motor Stator Assembly 120301-N0602-575-2 1 Winding Machine T1 Assembly, Mark-up Applied 

@ Bottom. Copper - Windings, <1mm Electromechanical Assembly Elec. Assembly, MHC, Base 199 0.5 3 1 0.930 $2.94 $36.21 $45.00 $135.00 $2.73 $0.09 $0.68 $3.51 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $3.51 $3.51 $2.73

3 1C H AC Compressor Motor Stator Assembly 120301-N0602-575-1 1 Install Stator Spacers T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Electromechanical Assembly Elec. Assembly, MC, Base 200 0.5 1 1 0.000 $0.00 $36.21 $30.00 $30.00 $0.00 $0.09 $0.15 $0.24 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.24 $0.24 $0.00

Assemble leads to coil winding T1 Assembly, Mark-up Applied 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

4 1D H AC Compressor Motor Stator Assembly 120301-N0602-575 1

Assemble leads to coil winding 

terminations.

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Electromechanical Assembly Elec. Assembly, LC, Base 200 6 1 6 0.000 $0.00 $36.21 $15.00 $90.00 $0.00 $1.09 $0.45 $1.54 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.54 $1.54 $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

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

1 1A H AC Motor Stator Plates - w/Alignment Notch & 

Holes 120301-N0602-550 13 Stamping T1 Assembly, Mark-up Applied @ Bottom. Si. Elect. Steel Cut/Punch/Forming Operator Stamp/Form, XSS 6000 0.5 1 1 0.043 $0.75 $42.73 $24.60 $24.60 $0.03 $0.00 $0.00 $0.04 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.04 $0.52 $0.42

2 0 ##### 0 1 1 0.203 #N/A #N/A #N/A #N/A #N/A #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 2A H AC Motor Stator Plates - w/1 Notch no holes 120301-N0602-551 17 Stamping T1 Assembly, Mark-up Applied 

@ Bottom. Si. Elect. Steel Cut/Punch/Forming Operator Stamp/Form, XSS 6000 0.5 1 1 0.043 $0.75 $42.73 $24.60 $24.60 $0.03 $0.00 $0.00 $0.04 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.04 $0.68 $0.55

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 3A H AC Motor Stator Plates - No notch 120301-N0602-552 144 Stamping T1 Assembly, Mark-up Applied 

@ Bottom. Si. Elect. Steel Cut/Punch/Forming Operator Stamp/Form, XSS 42000 3 7 1 0.043 $0.75 $42.73 $24.60 $172.20 $0.03 $0.00 $0.00 $0.04 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.04 $5.67 $4.64

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 4A H AC Motor Stator Plates - 3 Notches no holes 120301-N0602-553 14 Stamping T1 Assembly, Mark-up Applied 

@ Bottom. Si. Elect. Steel Cut/Punch/Forming Operator Stamp/Form, XSS 6000 0.5 1 1 0.043 $0.75 $42.73 $24.60 $24.60 $0.03 $0.00 $0.00 $0.04 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.04 $0.56 $0.45

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 5A H AC Motor Stator Plates - 3 Notches plus holes 120301-N0602-554 15 Stamping T1 Assembly, Mark-up Applied 

@ Bottom. Si. Elect. Steel Cut/Punch/Forming Operator Stamp/Form, XSS 6000 0.5 1 1 0.043 $0.75 $42.73 $24.60 $24.60 $0.03 $0.00 $0.00 $0.04 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.04 $0.60 $0.48

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 6A H AC Motor Stator Stack 120301-N0602-555-0 1

Stacking process of stator 

plates

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Electromechanical Assembly Elec. Assembly, LC, Base 180 0.5 1 14 0.000 $0.00 $36.21 $15.00 $210.00 $0.00 $0.10 $1.17 $1.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.27 $1.27 $0.00

12 6B H AC Motor Stator Stack 120301-N0602-555-01 1 Machining of stacked stator T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Electromechanical Assembly CNC Turning, SMS, AL, QA 180 0.5 1 1 0.000 $0.00 $36.21 $31.75 $31.75 $0.00 $0.10 $0.18 $0.28 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.28 $0.28 $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 7A H AC Motor Stator Base 120301-N0602-556 1 Injection Mold T1 Assembly, Mark-up Applied 

@ Bottom. Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 692 0.25 1 1 0.042 $1.54 $41.48 $28.80 $28.80 $0.06 $0.01 $0.04 $0.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.12 $0.12 $0.06

15 8A H AC Motor Stator Top 120301-N0602-557 1 Injection Mold T1 Assembly, Mark-up Applied 

@ Bottom. 15 8A H AC Motor Stator Top 120301-N0602-557 1 Injection Mold Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 621 0.25 1 1 0.050 $1.54 $41.48 $28.80 $28.80 $0.08 $0.02 $0.05 $0.14 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.14 $0.14 $0.08 @ Bottom. Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 621 0.25 1 1 0.050 $1.54 $41.48 $28.80 $28.80 $0.08 $0.02 $0.05 $0.14 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.14 $0.14 $0.08

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 9A H AC Motor Stator Top 120301-N0602-558 1 Injection Mold T1 Assembly, Mark-up Applied 

@ Bottom. Nylon66-30GF, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS 692 0.25 1 1 0.047 $1.54 $41.48 $28.80 $28.80 $0.07 $0.01 $0.04 $0.13 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.13 $0.13 $0.07

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

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 1A H AC Motor Stator Insulator Liners 120301-N0602-565 9

Aromatic polyimide Film (e.g. 

Aramid) S $0.00 $0.124 $0.00 $1.12 $1.12 "S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-575 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

3 2A H AC Motor Stator Insulator Spaces 120301-N0602-566 9

Aromatic polyimide Film (e.g. 

Aramid) S $0.00 $0.06 $0.00 $0.56 $0.56

3 3A H AC Individual Wire Insulators 120301-N0602-567 9 3x3 (Red, White, Black) S $0.00 $0.01 $0.00 $0.09 $0.09

4 4A H AC Group Insulators 120301-N0602-568 3 (Red, White Black) S $0.00 $0.02 $0.00 $0.05 $0.05

5 5A Female Spade Terminals and Covers 120301-N0602-569 3 S $0.00 $0.10 $0.00 $0.30 $0.30

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

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

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

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

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

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

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.

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

Material

$11.61

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

Mark-up $17.67

T1 or OEM Total Manufacturing Cost: $11.61 $2.26 $3.81 $17.67 $0.00 $0.00 $0.00 $0.00 $0.00 $17.67

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 ----- ----- ----- $0.09 $1.15 $1.06 $0.44 $2.74

Base Cost Impact to Vehicle: $11.61 $2.26 $3.81 $17.67 $0.09 $1.15 $1.06 $0.44 $2.74 $20.41 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $20.41

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

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

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

S. 020909)

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) Piece Price Per Pallet/Rack Price Per Pallet/Rack Price Per Pallet/Rack Price Per Pallet/Rack Price Per 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

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

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

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

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

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-575 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

1A H AC Compressor Motor Stator Assembly 120301-N0602-575-3

1B H AC Compressor Motor Stator Assembly 120301-N0602-575-2

1C H AC Compressor Motor Stator Assembly 120301-N0602-575-1

GENERAL COMPONENT INFORMATION

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

20

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

$0.09 $0.23 $0.32 $0.00 $0.00 $0.00 $0.00 $0.00 Slot Liner Insertion Machine, Automatic load/unload, Cycle Time 1 liner/second, 3 seconds load, 2 clamp 

and initiate process, 2 unclamp, 2 seconds buffer 2.5 2 10 50 47 2350 191 18.80 85% 225 15.98 22 1 1 18 1.5 1.0 200 18.00 0.50

$0.09 $0.68 $3.51 $0.00 $0.00 $0.00 $0.00 $0.00 Automated winding station, auto load and clamp, cut and position leads. 2.5 2 10 50 47 2350 191 18.80 85% 225 15.98 23 1 1 54.38 1.0 3.0 199 18.13 0.50

$0.09 $0.15 $0.24 $0.00 $0.00 $0.00 $0.00 $0.00 Slot Spacer Insertion Machine, Automatic load/unload, Cycle Time 1 liner/second, 3 seconds load, 2 clamp 

and initiate process, 2 unclamp, 2 seconds buffer. 2.5 2 10 50 47 2350 191 18.80 85% 225 15.98 45 1 1 18 1.0 1.0 200 18.00 0.50

Semi-automated assembly line (Automated handling and assist, manual assembly), S#1 wrap and 

orientate termination leads to upper molded base, S#2 secure terminations leads together with polyester 

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

1D H AC Compressor Motor Stator Assembly 120301-N0602-575

Purchase Part - High Impact Item (Full Cost Mapping)

1A H AC Motor Stator Plates - w/Alignment Notch & 

Holes 120301-N0602-550

2A H AC Motor Stator Plates - w/1 Notch no holes 120301-N0602-551

3A H AC Motor Stator Plates - No notch 120301-N0602-552

4A H AC Motor Stator Plates - 3 Notches no holes 120301-N0602-553

5A H AC Motor Stator Plates - 3 Notches plus holes 120301-N0602-554

6A H AC Motor Stator Stack 120301-N0602-555-0

6B H AC Motor Stator Stack 120301-N0602-555-01

7A H AC Motor Stator Base 120301-N0602-556

8A H AC Motor Stator Top 120301-N0602-557

$1.09 $0.45 $1.54 $0.00 $0.00 $0.00 $0.00 $0.00

orientate termination leads to upper molded base, S#2 secure terminations leads together with polyester 

lacing cord, S#3, slide individual insulator sleeves over leads, S# 4 slide group insulator sleeves and 

terminal isolators over leads, S#5 Crimp terminal ends on grouped wires (x3), S#6 Functional test, snap 

on end cap, position isolators over terminals, and pack.

2.5 2 10 50 47 2350 191 18.80 85% 225 15.98 118 6 1 18 6.0 1.0 200 18.00 6.00

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

$0.05 $0.05 $0.52 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive stamping die in-line with automatic stator disc stacking equipment. 2 2 10 40 47 1880 3112 1.16 85% 3661 0.98 0.6 1 1 0.6 1.0 1.0 6000 0.60 0.50

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 1 2 10 20 47 940 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.06 $0.07 $0.68 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive stamping die in-line with automatic stator disc stacking equipment. 2 2 10 40 47 1880 4069 0.88 85% 4787 0.75 0.6 1 1 0.6 1.0 1.0 6000 0.60 0.50

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

$0.44 $0.59 $5.67 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive stamping die in-line with automatic stator disc stacking equipment. 2 2 10 40 47 1880 34468 0.10 85% 40551 0.09 0.6 1 1 0.6 1.0 7.0 42000 0.09 3.00

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

$0.05 $0.06 $0.56 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive stamping die in-line with automatic stator disc stacking equipment. 2 2 10 40 47 1880 3351 1.07 85% 3942 0.91 0.6 1 1 0.6 1.0 1.0 6000 0.60 0.50

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

$0.05 $0.06 $0.60 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive stamping die in-line with automatic stator disc stacking equipment. 2 2 10 40 47 1880 3590 1.00 85% 4224 0.85 0.6 1 1 0.6 1.0 1.0 6000 0.60 0.50

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

$0.10 $1.17 $1.27 $0.00 $0.00 $0.00 $0.00 $0.00 Rotary transfer table with automatic load/load, stack and press, 14 stations (13 press, 1 unload) 20 

seconds per station (17 work, 3 transfer and clamp) 2 2 10 40 47 1880 239 15.04 85% 282 12.78 - 1 1 20.0 14.0 1.0 180 20.00 0.50

$0.10 $0.18 $0.28 $0.00 $0.00 $0.00 $0.00 $0.00 CNC Turning Machine, auto load/unload, buffer between stacking and machining. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 20 1.0 1.0 180 20.00 0.50

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

$0.01 $0.04 $0.12 $0.00 $0.00 $0.00 $0.00 $0.00 4 cavity Injection mold 1 2 10 20 47 940 479 7.52 85% 563 6.39 5.2 1 4 21 1.0 1.0 692 5.20 0.25

8A H AC Motor Stator Top 120301-N0602-557 $0.02 $0.05 $0.14 $0.00 $0.00 $0.00 $0.00 $0.00 4 cavity Injection mold 1 2 10 20 47 940 479 7.52 85% 563 6.39 5.8 1 4 23.2 1.0 1.0 621 5.80 0.25

9A H AC Motor Stator Top 120301-N0602-558

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

1A H AC Motor Stator Insulator Liners 120301-N0602-565

$0.02 $0.05 $0.14 $0.00 $0.00 $0.00 $0.00 $0.00 4 cavity Injection mold 1 2 10 20 47 940 479 7.52 85% 563 6.39 5.8 1 4 23.2 1.0 1.0 621 5.80 0.25

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

$0.01 $0.04 $0.13 $0.00 $0.00 $0.00 $0.00 $0.00 4 cavity Injection mold 1 2 10 20 47 940 479 7.52 85% 563 6.39 5.2 1 4 20.8 1.0 1.0 692 5.20 0.25

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

$1.12

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

2A H AC Motor Stator Insulator Spaces 120301-N0602-566

3A H AC Individual Wire Insulators 120301-N0602-567

4A H AC Group Insulators 120301-N0602-568

5A Female Spade Terminals and Covers 120301-N0602-569

20

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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

$0.56

$0.09

$0.05

$0.30

$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

$2.26 $3.81 $17.67 $0.00 $0.00 $0.00 $0.00 $0.00

$17.67

2

Notes: 

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

20

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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: 1 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-398 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

1 1A H AC Board 2 120301-N0602-398-4 1 SMT Line, Bottom Side T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Electrical Assembly SMT, Medium Content 311 2 1 1 0.000 $0.00 $29.83 $218.25 $218.25 $0.00 $0.19 $0.70 $0.89 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.89 $0.89 $0.00

2 1B H AC Board 2 120301-N0602-398-3 1 SMT Line, Top Side T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Electrical Assembly SMT, Medium Content 311 2 1 1 0.000 $0.00 $29.83 $218.25 $218.25 $0.00 $0.19 $0.70 $0.89 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.89 $0.89 $0.00

3 1C HAC Board 2 120301-N0602-398-2 1 Thru Hole, Top & Bottom T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Electrical Assembly Thru Hole, Manual 477 4 2 2 0.000 $0.00 $29.83 $23.00 $92.00 $0.00 $0.25 $0.19 $0.44 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.44 $0.44 $0.00

T1 Assembly, Mark-up Applied 

Costs Broken Out In

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

4 1D HAC Board 2 120301-N0602-398-1 1 Functional Test T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Electrical Assembly EOL Func.Test, Medium Content 320 0 1 1 0.000 $0.00 $29.83 $28.18 $28.18 $0.00 $0.00 $0.09 $0.09 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.09 $0.09 $0.00

5 1E HAC Board 2 120301-N0602-398 1 Depanel T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Electrical Assembly De-Panel, In-Line, Router 557 1 1 1.795 0.000 $0.00 $29.83 $24.38 $43.76 $0.00 $0.05 $0.08 $0.13 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.13 $0.13 $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

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 H AC Board 1 Bare FR4 120301-N0602-355 1 FR4 S $0.00 $3.41 $0.00 $3.41 $3.41

2 BOTTOM SIDE COMPONENTS 120301-N0602-356 $0.00 $0.00 $0.00 $0.00

3 IC H8 MCU FLASH 256K 100TQFP 120301-N0602-357 1 64F7047FRK40 S $0.00 $12.30 $0.00 $12.30 $12.30

4 IC - OP Amp 120301-N0602-358 1 TY2464A S $0.00 $0.40 $0.00 $0.40 $0.40

5 IC - Voltage Regulator 120301-N0602-359 1 4274DV5 S $0.00 $1.29 $0.00 $1.29 $1.29

6 IC - OPTOCOUPLER 120301-N0602-360 1 M6IT 803 00 S $0.00 $0.92 $0.00 $0.92 $0.92

7 IC - OPTOCOUPLER 120301-N0602-361 1 M6IT 803 00 S $0.00 $0.92 $0.00 $0.92 $0.92

8 IC - Optoisolators 120301-N0602-362 1 M43T 749 01 S $0.00 $0.92 $0.00 $0.92 $0.92

9 IC - Transceiver 120301-N0602-363 1 H1050Q 07CT A4L1G4 S $0.00 $0.84 $0.00 $0.84 $0.84

10 Diode 120301-N0602-364 1 E85 S $0.00 $0.15 $0.00 $0.15 $0.15

11 IC - Digital to Analog Converter 120301-N0602-365 1 9001FNG 810A4 S $0.00 $2.33 $0.00 $2.33 $2.33

12 Zener Diode 120301-N0602-366 1 51 S $0.00 $0.07 $0.00 $0.07 $0.07

13 IC - Bridge Rectifier 120301-N0602-367 1 L273 S $0.00 $0.07 $0.00 $0.07 $0.07

14 IC Unmarked 120301-N0602-368 2 IC Unmarked S $0.00 $0.00 $0.00 $0.00 $0.00

15 MOSFET 120301-N0602-369 2 MOSFET S $0.00 $0.06 $0.00 $0.12 $0.12

16 Chip Resistor - Surface Mount 120301-N0602-370 1 100 S $0.00 $0.02 $0.00 $0.02 $0.02

17 Chip Resistor - Surface Mount 120301-N0602-371 1 101 S $0.00 $0.02 $0.00 $0.02 $0.02

18 Inductor 120301-N0602-372 1 221 S $0.00 $0.70 $0.00 $0.70 $0.70

19 Inductor 120301-N0602-373 1 221 S $0.00 $0.70 $0.00 $0.70 $0.70

20 10000 KSS807F 120301-N0602-374 1 10000 KSS807F S $0.00 $0.33 $0.00 $0.33 $0.33

21 MOSFET 120301-N0602-375 1 S93A66 ADAVH4 1439 S $0.00 $1.18 $0.00 $1.18 $1.18

"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.

21 MOSFET 120301-N0602-375 1 S93A66 ADAVH4 1439 S $0.00 $1.18 $0.00 $1.18 $1.18

22 Diode 120301-N0602-376 1 T7D S $0.00 $0.05 $0.00 $0.05 $0.05

23 Schottky Diode 120301-N0602-377 1 Schottky Diode S $0.00 $0.07 $0.00 $0.07 $0.07

24 Capacitors 120301-N0602-378 47 Capacitors S $0.00 $0.01 $0.00 $0.47 $0.47

25 Resistors 120301-N0602-379 61 Resistors S $0.00 $0.01 $0.00 $0.61 $0.61

26 TOP SIDE COMPONETS 120301-N0602-380 1 $0.00 $0.00 $0.00 $0.00

27 Aluminum Capacitor - SM 120301-N0602-381 8 PCE3155TR-ND S $0.00 $0.32 $0.00 $2.56 $2.56

28 Aluminum Capacitor - SM 120301-N0602-382 1 PCE3146TR-ND S $0.00 $0.32 $0.00 $0.32 $0.32

29 Aluminum Capacitor - SM 120301-N0602-383 1 PCE3156TR-ND S $0.00 $0.37 $0.00 $0.37 $0.37

30 Zener Diode - SM 120301-N0602-384 1 ST70-27MF S $0.00 $0.02 $0.00 $0.02 $0.02

31 Transistors (BJT) - SM 120301-N0602-385 1 "2SC3303-O(T6L1,NQ)-ND" S $0.00 $0.47 $0.00 $0.47 $0.47

32 Zener Diode - SM 120301-N0602-386 2 BZX84C27-FDITR-ND S $0.00 $0.02 $0.00 $0.04 $0.04

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-398 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

33 Diode 120301-N0602-387 1 "TE85L,Q,M" S $0.00 $0.15 $0.00 $0.15 $0.15

34 IC REG LDO 400MA 5.0V DPAK 120301-N0602-388 1 NCV4274ADT33RKGOSTR-ND S $0.00 $1.30 $0.00 $1.30 $1.30

35 Zener Diode 120301-N0602-389 1 MMSZ4679T1GOSTR-ND S $0.00 $0.02 $0.00 $0.02 $0.02

36 Schottky Diode 120301-N0602-390 2 BAT 63-02V E6327-ND-1 S $0.00 $0.11 $0.00 $0.22 $0.22

37 Transformer - SM 120301-N0602-391 1 257-1149-1-ND S $0.00 $1.92 $0.00 $1.92 $1.92

38 Schottky Diode 120301-N0602-392 1 641-1255-2-ND S $0.00 $0.18 $0.00 $0.18 $0.18

39 Capacitors 120301-N0602-393 57 Capacitors S $0.00 $0.01 $0.00 $0.57 $0.57

40 Resistors 120301-N0602-394 28 Resistors S $0.00 $0.01 $0.00 $0.28 $0.28

41 THRU HOLE COMPONENTS 120301-N0602-395 $0.00 $0.00 $0.00 $0.00

42 Connector Asm - 8 position 120301-N0602-396 1 12124898 S $0.00 $2.25 $0.00 $2.25 $2.25

43 Header - 22 position 120301-N0602-397 1 SAM1111-22-ND S $0.00 $1.85 $0.00 $1.85 $1.85

44 0 $0.00 $0.00 $0.00 $0.00

Material

$40.41

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

Mark-up $42.86

T1 or OEM Total Manufacturing Cost: $40.41 $0.69 $1.77 $42.86 $0.00 $0.00 $0.00 $0.00 $0.00 $42.86

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

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.21 $2.79 $2.57 $1.07 $6.64

Base Cost Impact to Vehicle: $40.41 $0.69 $1.77 $42.86 $0.21 $2.79 $2.57 $1.07 $6.64 $49.51 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $49.51

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:

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Cost per Tote: $75/Tote

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

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

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

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-398 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

Purchase Part - High Impact Item (Full Cost Mapping)

1A H AC Board 2 120301-N0602-398-4

1B H AC Board 2 120301-N0602-398-3

1C HAC Board 2 120301-N0602-398-2

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

$0.19 $0.70 $0.89 $0.00 $0.00 $0.00 $0.00 $0.00 Section 1 of line SMT 2 2 10 40 47 1880 239 15.04 85% 282 12.78 15.8 1 16 185.5 1.0 1.0 311 11.59 2.00

$0.19 $0.70 $0.89 $0.00 $0.00 $0.00 $0.00 $0.00 Section 2 of line, SMT 2 2 10 40 47 1880 239 15.04 85% 282 12.78 15.8 1 16 185.5 1.0 1.0 311 11.59 2.00

$0.25 $0.19 $0.44 $0.00 $0.00 $0.00 $0.00 $0.00 Section 3 of line, thru hole and wave solder 2 2 10 40 47 1880 239 15.04 85% 282 12.78 23 1 16 241.5 2.0 2.0 477 7.55 4.00

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

1D HAC Board 2 120301-N0602-398-1

1E HAC Board 2 120301-N0602-398

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

H AC Board 1 Bare FR4 120301-N0602-355

BOTTOM SIDE COMPONENTS 120301-N0602-356

IC H8 MCU FLASH 256K 100TQFP 120301-N0602-357

IC - OP Amp 120301-N0602-358

IC - Voltage Regulator 120301-N0602-359

IC - OPTOCOUPLER 120301-N0602-360

IC - OPTOCOUPLER 120301-N0602-361

IC - Optoisolators 120301-N0602-362

IC - Transceiver 120301-N0602-363

Diode 120301-N0602-364

IC - Digital to Analog Converter 120301-N0602-365

Zener Diode 120301-N0602-366

IC - Bridge Rectifier 120301-N0602-367

IC Unmarked 120301-N0602-368

MOSFET 120301-N0602-369

Chip Resistor - Surface Mount 120301-N0602-370

Chip Resistor - Surface Mount 120301-N0602-371

Inductor 120301-N0602-372

Inductor 120301-N0602-373

10000 KSS807F 120301-N0602-374

MOSFET 120301-N0602-375

$0.00 $0.09 $0.09 $0.00 $0.00 $0.00 $0.00 $0.00 Section 4 Functional Test, Auto/Load Unload 2 2 10 40 47 1880 239 15.04 85% 282 12.78 35.0 1 16 180.0 1.0 1.0 320 11.25 -

$0.05 $0.08 $0.13 $0.00 $0.00 $0.00 $0.00 $0.00 Section 5 De-paneling station, operator unload 2 2 10 40 47 1880 239 15.04 85% 282 12.78 12.4 1 16 103.3 1.8 1.0 557 6.46 1.00

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

$3.41

$0.00

$12.30

$0.40

$1.29

$0.92

$0.92

$0.92

$0.84

$0.15

$2.33

$0.07

$0.07

$0.00

$0.12

$0.02

$0.02

$0.70

$0.70

$0.33

MOSFET 120301-N0602-375 $1.18

Diode 120301-N0602-376

Schottky Diode 120301-N0602-377

Capacitors 120301-N0602-378

Resistors 120301-N0602-379

TOP SIDE COMPONETS 120301-N0602-380

Aluminum Capacitor - SM 120301-N0602-381

Aluminum Capacitor - SM 120301-N0602-382

Aluminum Capacitor - SM 120301-N0602-383

Zener Diode - SM 120301-N0602-384

Transistors (BJT) - SM 120301-N0602-385

Zener Diode - SM 120301-N0602-386

$1.18

$0.05

$0.07

$0.47

$0.61

$0.00

$2.56

$0.32

$0.37

$0.02

$0.47

$0.04

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

Diode 120301-N0602-387

IC REG LDO 400MA 5.0V DPAK 120301-N0602-388

Zener Diode 120301-N0602-389

Schottky Diode 120301-N0602-390

Transformer - SM 120301-N0602-391

Schottky Diode 120301-N0602-392

Capacitors 120301-N0602-393

Resistors 120301-N0602-394

THRU HOLE COMPONENTS 120301-N0602-395

Connector Asm - 8 position 120301-N0602-396

Header - 22 position 120301-N0602-397

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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

$0.15

$1.30

$0.02

$0.22

$1.92

$0.18

$0.57

$0.28

$0.00

$2.25

$1.85

$0.00

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

Total

$0.69 $1.77 $42.86 $0.00 $0.00 $0.00 $0.00 $0.00

$42.86

2

Notes: 

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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: 1 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-299 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

1 1A Final Assembly Line 120301-N0602-299 1

Final Assembly of PEB to IGBT 

subassembly

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Electrical Assembly Elec. Assembly, MC, Base 180 3 1 6 0.000 $0.00 $29.83 $30.00 $180.00 $0.00 $0.50 $1.00 $1.50 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.50 $1.50 $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 1A H AC PCB 2 Base plate Assembly 120301-N0602-300-3 1 Stamping T1 Assembly, Mark-up Applied Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, XSS 766 0.25 1 1 0.259 $0.84 $42.73 $24.60 $24.60 $0.22 $0.01 $0.03 $0.26 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.26 $0.26 $0.22

Costs Broken Out In

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

1 1A H AC PCB 2 Base plate Assembly 120301-N0602-300-3 1 Stamping T1 Assembly, Mark-up Applied 

@ Bottom. Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, XSS 766 0.25 1 1 0.259 $0.84 $42.73 $24.60 $24.60 $0.22 $0.01 $0.03 $0.26 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.26 $0.26 $0.22

2 1B H AC PCB 2 Base plate Assembly 120301-N0602-300-2 1 Machine T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Dedicated Machining Center - Single Station, LC, Base 98 1 1 1 0.000 $0.00 $42.73 $30.38 $30.38 $0.00 $0.44 $0.31 $0.75 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.75 $0.75 $0.00

3 1C H AC PCB 2 Base plate Assembly 120301-N0602-300-1 1 Wash T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Cut/Punch/Forming Operator Washing Equipment, LC 450 0.25 1 1 0.000 $0.00 $42.73 $10.75 $10.75 $0.00 $0.02 $0.02 $0.05 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.05 $0.05 $0.00

4 1D IGBT Isolator 0

T1 Assembly, Mark-up Applied 

@ Bottom. ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A 0.00% 0.00% 0.00% 0.00% 0.00% #N/A #N/A $0.00 $0.00

5 2A H AC Board 2 120301-N0602-301-1 1 SMT Line, Bottom Side T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Electrical Assembly SMT, Medium Content 655 2 1 1 0.000 $0.00 $29.83 $218.25 $218.25 $0.00 $0.09 $0.33 $0.42 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.42 $0.42 $0.00

6 2B H AC Board 2 120301-N0602-301-2 1 SMT Line, Top Side T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Electrical Assembly SMT, Medium Content 655 2 1 1 0.000 $0.00 $29.83 $218.25 $218.25 $0.00 $0.09 $0.33 $0.42 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.42 $0.42 $0.00

7 2C HAC Board 2 120301-N0602-301-3 1 Thru Hole, Top & Bottom T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Electrical Assembly Thru Hole, Manual 713 3 3 2 0.000 $0.00 $29.83 $23.00 $138.00 $0.00 $0.13 $0.19 $0.32 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.32 $0.32 $0.00

8 2D HAC Board 2 120301-N0602-301-4 1 Functional Test T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Electrical Assembly EOL Func.Test, Medium Content 655 0 2 1 0.000 $0.00 $29.83 $28.18 $56.36 $0.00 $0.00 $0.09 $0.09 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.09 $0.09 $0.00

8 2E HAC Board 2 120301-N0602-301-5 1 Depanel T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Electrical Assembly De-Panel, In-Line, Router 643 1 1 1 0.000 $0.00 $29.83 $24.38 $24.38 $0.00 $0.05 $0.04 $0.08 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.08 $0.08 $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

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 1A IC IGBT - Screw Attachment 120301-N0602-325 6 IRGP30B60KD-EP-ND S $0.00 $3.87 $0.00 $23.22 $23.22

2 2A H Screw IGBT to base 120301-N0602-326 6 S $0.00 $0.02 $0.00 $0.12 $0.12

3 3A H screw AC PCB 2 wire lead 120301-N0602-327 1 S $0.00 $0.01 $0.00 $0.01 $0.01

4 4A H Screw IGBT to base 120301-N0602-328 4 S $0.00 $0.02 $0.00 $0.08 $0.08

5 5A IGBT isolator pad 120301-N0602-329 1 S $0.00 $0.35 $0.00 $0.35 $0.35

6 6A FR4 (Two Layer) 120301-N0602-330 1 H AC Board 2 Bare FR4 S $0.00 $2.64 $0.00 $2.64 $2.64

7 7 Bottom BOTTOM SMT $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.

Missing Silver Box and 

Pig Tail in BOM

8 7A Chip Resistor - Surface Mount 120301-N0602-331 6 RHM. 002AUTR-ND S $0.00 $0.29 $0.00 $1.74 $1.74

9 7B Chip Resistor 120301-N0602-332 3 541-1. 0XTR-ND S $0.00 $0.03 $0.00 $0.09 $0.09

10 7C Capacitors 120301-N0602-333 19 Capacitors S $0.00 $0.01 $0.00 $0.19 $0.19

11 7D Resistors 120301-N0602-334 19 Resistors S $0.00 $0.01 $0.00 $0.19 $0.19

12 8 Top TOP SMT $0.00 $0.00 $0.00 $0.00

13 8A Aluminum Capacitor - SM 120301-N0602-335 1 PCE3155TR-ND S $0.00 $0.32 $0.00 $0.32 $0.32

14 8B Aluminum Capacitor - SM 120301-N0602-336 1 PCE3155TR-ND S $0.00 $0.32 $0.00 $0.32 $0.32

15 8C Aluminum Capacitor - SM 120301-N0602-337 1 PCE3155TR-ND S $0.00 $0.32 $0.00 $0.32 $0.32

16 8D IC 120301-N0602-338 1 IR2113SPBFC T-ND-1 S $0.00 $1.15 $0.00 $1.15 $1.15

17 8E IC 120301-N0602-339 1 IR2113SPBFC T-ND-1 S $0.00 $1.15 $0.00 $1.15 $1.15

18 8F IC 120301-N0602-340 1 IR2113SPBFC T-ND-1 S $0.00 $1.15 $0.00 $1.15 $1.15

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

Supplier for Subassembly.

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-299 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

19 8G IC - OP Amp 120301-N0602-341 1 TLV2464AIPW S $0.00 $1.48 $0.00 $1.48 $1.48

20 8H MOSFET 120301-N0602-342 1 BSS84CT-ND S $0.00 $0.06 $0.00 $0.06 $0.06

21 8I Chip Resistor - Surface Mount 120301-N0602-343 3 HVCB1206T21 00MFICT-ND S $0.00 $2.80 $0.00 $8.40 $8.40

22 8J Chip Resistor - Surface Mount 120301-N0602-344 4 HMC1/8200MK R-ND S $0.00 $0.51 $0.00 $2.04 $2.04

23 8K Chip Resistor - Surface Mount 120301-N0602-345 2 CRCW201030 0RFKTF-ND S $0.00 $0.09 $0.00 $0.18 $0.18

24 8K Schottky Diode Type - SM 120301-N0602-346 3 MA2Q70500L CT-ND S $0.00 $0.29 $0.00 $0.87 $0.87

25 8M Capacitors 120301-N0602-347 14 Capacitors S $0.00 $0.01 $0.00 $0.14 $0.14

26 8N Resistors 120301-N0602-348 36 Resistors S $0.00 $0.01 $0.00 $0.36 $0.36

27 9 Thru Hole THRU HOLE $0.00 $0.00 $0.00 $0.00

28 9A Connector - 2 pin 120301-N0602-349 1 H AC Board 2 Connector - 2 pin S $0.00 $0.15 $0.00 $0.15 $0.15

29 9B Connetor - 4 pin (blade) 120301-N0602-350 1 H AC Board 2 Connetor - 4 pin (blade) S $0.00 $0.20 $0.00 $0.20 $0.20

30 9C Header - 22 position Header - 22 position 120301-N0602-351 120301-N0602-351 1 SAM1111-22-ND SAM1111-22-ND S $0.00 $1.85 $0.00 $1.85 $1.85

Material

$48.99

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

Mark-up $52.66

T1 or OEM Total Manufacturing Cost: $48.99 $1.32 $2.35 $52.66 $0.00 $0.00 $0.00 $0.00 $0.00 $52.66

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

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.26 $3.42 $3.16 $1.32 $8.16

Base Cost Impact to Vehicle: $48.99 $1.32 $2.35 $52.66 $0.26 $3.42 $3.16 $1.32 $8.16 $60.83 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $60.83

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:

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Cost per Tote: $75/Tote

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

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

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

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-299 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

1A Final Assembly Line 120301-N0602-299

Purchase Part - High Impact Item (Full Cost Mapping)

1A H AC PCB 2 Base plate Assembly 120301-N0602-300-3

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

$0.50 $1.00 $1.50 $0.00 $0.00 $0.00 $0.00 $0.00

Final Assembly (Line 2 Parts per fixture), S#1 (M) Operator load isolator pad and IGBT's, Station #2, Auto 

Rundown, 6 spindle tool, shuttle tool, S#3 (M) Operator assembly PEB to IGBT subassembly, manual 

rundown wire lead, Station #4 Auto rundown PEB to IGBT subassembly 4 spindle tool, shuttle tool, S#5 

Point Solder, dual head 1/fixture, S#6 (M) Functional Test and Unload

5 2 10 100 47 4700 96 37.60 85% 113 31.96 180 6 2 40 6.0 1.0 180 20.00 3.00

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

$0.01 $0.03 $0.26 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive Die, One off 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1.7 1 1 4.7 1.0 1.0 766 4.70 0.25

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

1A H AC PCB 2 Base plate Assembly 120301-N0602-300-3

1B H AC PCB 2 Base plate Assembly 120301-N0602-300-2

1C H AC PCB 2 Base plate Assembly 120301-N0602-300-1

1D IGBT Isolator 

2A H AC Board 2 120301-N0602-301-1

2B H AC Board 2 120301-N0602-301-2

2C HAC Board 2 120301-N0602-301-3

2D HAC Board 2 120301-N0602-301-4

2E HAC Board 2 120301-N0602-301-5

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

1A IC IGBT - Screw Attachment 120301-N0602-325

2A H Screw IGBT to base 120301-N0602-326

3A H screw AC PCB 2 wire lead 120301-N0602-327

4A H Screw IGBT to base 120301-N0602-328

5A IGBT isolator pad 120301-N0602-329

6A FR4 (Two Layer) 120301-N0602-330

7 Bottom

$0.01 $0.03 $0.26 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive Die, One off 5 2 10 100 47 4700 96 37.60 85% 113 31.96 1.7 1 1 4.7 1.0 1.0 766 4.70 0.25

$0.44 $0.31 $0.75 $0.00 $0.00 $0.00 $0.00 $0.00 Semi dedicated machining center, shuttle station, single spindle, operator load & unload 5.5 2 10 110 47 5170 87 41.36 85% 102 35.16 45.7 2 1 36.70 1.0 1.0 98 36.70 1.00

$0.02 $0.02 $0.05 $0.00 $0.00 $0.00 $0.00 $0.00 Batch wash, time shown corresponds to allocation for single part 5 2 10 100 47 4700 96 37.60 85% 113 31.96 8 1 1 8 1.0 1.0 450 8.00 0.25

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

$0.09 $0.33 $0.42 $0.00 $0.00 $0.00 $0.00 $0.00 Section 1 of line SMT 1 2 10 20 47 940 479 7.52 85% 563 6.39 9.6 1 20 110.0 1.0 1.0 655 5.50 2.00

$0.09 $0.33 $0.42 $0.00 $0.00 $0.00 $0.00 $0.00 Section 2 of line, SMT 1 2 10 20 47 940 479 7.52 85% 563 6.39 9.6 1 20 110.0 1.0 1.0 655 5.50 2.00

$0.13 $0.19 $0.32 $0.00 $0.00 $0.00 $0.00 $0.00 Section 3 of line, thru hole and wave solder, one automated and on maual station per line. 1 2 10 20 47 940 479 7.52 85% 563 6.39 38 1 20 303 2.0 3.0 713 5.05 3.00

$0.00 $0.09 $0.09 $0.00 $0.00 $0.00 $0.00 $0.00 Section 4 Functional Test, x20 array, Automated Load/Unload 1 2 10 20 47 940 479 7.52 85% 563 6.39 35.0 1 20 220.0 1.0 2.0 655 5.50 -

$0.05 $0.04 $0.08 $0.00 $0.00 $0.00 $0.00 $0.00 Section 5 De-paneling station, operator unload 1 2 10 20 47 940 479 7.52 85% 563 6.39 10.4 1 20 112.0 1.0 1.0 643 5.60 1.00

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

$23.22

$0.12

$0.01

$0.08

$0.35

$2.64

$0.00

7A Chip Resistor - Surface Mount 120301-N0602-331

7B Chip Resistor 120301-N0602-332

7C Capacitors 120301-N0602-333

7D Resistors 120301-N0602-334

8 Top

8A Aluminum Capacitor - SM 120301-N0602-335

8B Aluminum Capacitor - SM 120301-N0602-336

8C Aluminum Capacitor - SM 120301-N0602-337

8D IC 120301-N0602-338

8E IC 120301-N0602-339

8F IC 120301-N0602-340

$1.74

$0.09

$0.19

$0.19

$0.00

$0.32

$0.32

$0.32

$1.15

$1.15

$1.15

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

8G IC - OP Amp 120301-N0602-341

8H MOSFET 120301-N0602-342

8I Chip Resistor - Surface Mount 120301-N0602-343

8J Chip Resistor - Surface Mount 120301-N0602-344

8K Chip Resistor - Surface Mount 120301-N0602-345

8K Schottky Diode Type - SM 120301-N0602-346

8M Capacitors 120301-N0602-347

8N Resistors 120301-N0602-348

9 Thru Hole

9A Connector - 2 pin 120301-N0602-349

9B Connetor - 4 pin (blade) 120301-N0602-350

9C Header - 22 position 120301-N0602-351

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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

$1.48

$0.06

$8.40

$2.04

$0.18

$0.87

$0.14

$0.36

$0.00

$0.15

$0.20

9C Header - 22 position 120301-N0602-351 $1.85

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

Total

$1.32 $2.35 $52.66 $0.00 $0.00 $0.00 $0.00 $0.00

$52.66

2

Notes: 

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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: 1 of 4 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

1 1A H Bracket AC PCB Connector 120301-N0602-399 1 Stamping Progressive Die T1 Assembly, Mark-up Applied 

@ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, XSS 1333 0.25 1 1.1 0.142 $0.45 $42.73 $24.60 $27.06 $0.06 $0.01 $0.02 $0.09 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.09 $0.09 $0.06

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 2A H Plate, Terminal Block Pass Through 120301-N0602-400 1 Stamping Progressive Die T1 Assembly, Mark-up Applied 

@ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, XSS 1333 0.25 1 1 0.203 $0.45 $42.73 $24.60 $24.60 $0.09 $0.01 $0.02 $0.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.12 $0.12 $0.09

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

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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

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 1A H Gasket Terminal Pass-through 120301-N0602-425 1 S $0.00 $0.40 $0.00 $0.40 $0.40

3 1B H Leads, Terminal Block Pass-through 120301-N0602-426 3 S $0.00 $0.15 $0.00 $0.45 $0.45

3 1C H Bolt, Terminal Block Pass-through 120301-N0602-427 2 S $0.00 $0.03 $0.00 $0.06 $0.06

4 2A H Inductor Asm, Coil, Large 120301-N0602-428 1 S $0.00 $1.50 $0.00 $1.50 $1.50

5 3A H Inductor Asm, Coil, Small 120301-N0602-429 1 S $0.00 $1.00 $0.00 $1.00 $1.00

6 4A H Capacitor, Large 120301-N0602-430 1 S $0.00 $1.25 $0.00 $1.25 $1.25

7 5A H Terminal Block Asm. 120301-N0602-431 1 S $0.00 $0.40 $0.00 $0.40 $0.40

8 6A H Terminal Interface Assembly 120301-N0602-432 1 S $0.00 $0.75 $0.00 $0.75 $0.75

9 7A H Bolt, Terminal Block Asm. 1 S $0.00 $0.03 $0.00 $0.03 $0.03

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

"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.

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

$6.00

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

Mark-up

1 $6.05

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 4 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

T1 or OEM Total Manufacturing Cost: $6.00 $0.02 $0.04 $6.05 $0.00 $0.00 $0.00 $0.00 $0.00 $6.05

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

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.03 $0.39 $0.36 $0.15 $0.94

Base Cost Impact to Vehicle: $6.00 $0.02 $0.04 $6.05 $0.03 $0.39 $0.36 $0.15 $0.94 $6.99 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $6.99

Total Number of Pallets/

Number of Parts per Pallet/Supplier, Customer and InRequirements (Weeks)Supplier, Customer and InPACKAGING CALCULATIONS: 

3

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

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

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 Cost Total: $0.000

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

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

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

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

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 4 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

Purchase Part - High Impact Item (Full Cost Mapping)

1A H Bracket AC PCB Connector 120301-N0602-399

2A H Plate, Terminal Block Pass Through 120301-N0602-400

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

$0.01 $0.02 $0.09 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive Stamping Die and Batch Wash 1 2 10 20 47 940 479 7.52 85% 563 6.39 0.7 1 1 2.7 1.1 1.0 1333 2.70 0.25

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

$0.01 $0.02 $0.12 $0.00 $0.00 $0.00 $0.00 $0.00 Progressive Stamping Die and Batch Wash 1 2 10 20 47 940 479 7.52 85% 563 6.39 0.7 1 1 2.7 1.0 1.0 1333 2.70 0.25

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/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 - Commodity ( Value taken from Purchase Part Database)

1A H Gasket Terminal Pass-through 120301-N0602-425

1B H Leads, Terminal Block Pass-through 120301-N0602-426

1C H Bolt, Terminal Block Pass-through 120301-N0602-427

2A H Inductor Asm, Coil, Large 120301-N0602-428

3A H Inductor Asm, Coil, Small 120301-N0602-429

4A H Capacitor, Large 120301-N0602-430

5A H Terminal Block Asm. 120301-N0602-431

6A H Terminal Interface Assembly 120301-N0602-432

7A H Bolt, Terminal Block Asm.

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

$0.40

$0.45

$0.06

$1.50

$1.00

$1.25

$0.40

$0.75

$0.03

$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

$0.02 $0.04 $6.05 $0.00 $0.00 $0.00 $0.00 $0.00

$6.05

2

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 4 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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

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: 1 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

1 1A H HV Harness Assembly, AC Compressor 120301-N0602-475 1 Build-up of wire harness T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Elec. Assembly, LC, Base 180 8 1 8 0.000 $0.00 $38.55 $15.00 $120.00 $0.00 $1.71 $0.67 $2.38 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.38 $2.38 $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

Costs Broken Out In

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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

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

1 0 ##### 0 1 1 0.142 #N/A #N/A #N/A #N/A #N/A #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 1A Copper Cable 120301-N0602-450 3 18" per cable S $0.00 $2.13 $0.00 $6.40 $6.40

3 2A Eyelet Termials 120301-N0602-451 2 S $0.00 $0.05 $0.00 $0.10 $0.10

3 2B Grounding Connector Stamped Sub 120301-N0602-452 2 S $0.00 $0.25 $0.00 $0.50 $0.50

4 2C ID Connector Seal (Orange) 120301-N0602-453 2 S $0.00 $0.03 $0.00 $0.05 $0.05

5 2D OD Connector Seal (Black) 120301-N0602-454 2 S $0.00 $0.03 $0.00 $0.05 $0.05

6 2E Shrink Wrap Terminal Lead 120301-N0602-455 2 (Black and Red) S $0.00 $0.01 $0.00 $0.02 $0.02

"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.

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

7 2F Die Cast Gland Bracket 120301-N0602-456 1 S $0.00 $0.50 $0.00 $0.50 $0.50

8 3A Blade Terminal 120301-N0602-457 2 S $0.00 $0.08 $0.00 $0.16 $0.16

9 3B Grounding Connector Crimp 120301-N0602-458 2 S $0.00 $0.10 $0.00 $0.20 $0.20

10 3C Grounding Connector Socket 120301-N0602-459 2 S $0.00 $0.20 $0.00 $0.40 $0.40

11 3D ID Connector Seal 120301-N0602-460 2 S $0.00 $0.03 $0.00 $0.06 $0.06

12 3E Connector Rear Cap 120301-N0602-461 2 S $0.00 $0.05 $0.00 $0.10 $0.10

13 3F Terminal Lock Tab 120301-N0602-462 2 S $0.00 $0.02 $0.01 $0.04 $0.04

14 3G Connector - AC Compressor to Main 120301-N0602-463 1 S $0.00 $0.24 $0.00 $0.24 $0.24

15 3H Shorting Key 120301-N0602-464 1 S $0.00 $0.01 $0.00 $0.01 $0.01

16 4A Orange Convolute Wrap (Split) 120301-N0602-465 1 S $0.00 $0.14 $0.00 $0.14 $0.14

17 5A Tape Convolute Wrap 120301-N0602-466 1 5 Place x 12" = 60" S $0.00 $0.06 $0.00 $0.06 $0.06

18 6A Wire Harness X-mas tree snap 120301-N0602-466 1 S $0.00 $0.08 $0.00 $0.08 $0.08

Mark-up Calculations.

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

Supplier for Subassembly.

18 6A Wire Harness X-mas tree snap 120301-N0602-466 1 S $0.00 $0.08 $0.00 $0.08 $0.08

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

$9.10

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

Mark-up $11.48

T1 or OEM Total Manufacturing Cost: $9.10 $1.71 $0.67 $11.48 $0.00 $0.00 $0.00 $0.00 $0.00 $11.48

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 ----- ----- ----- $0.06 $0.75 $0.69 $0.29 $1.78

Base Cost Impact to Vehicle: $9.10 $1.71 $0.67 $11.48 $0.06 $0.75 $0.69 $0.29 $1.78 $13.26 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $13.26

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

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

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.

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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

Packaging Cost Total: $0.000

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

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

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

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

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

1A H HV Harness Assembly, AC Compressor 120301-N0602-475

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

$1.71 $0.67 $2.38 $0.00 $0.00 $0.00 $0.00 $0.00

Semi automated work cells, gravity fed part transfer, S#1A&S#1B load connector rear cap, seal and 

grounding connector onto wire (blade end), strip insulator @ core and shield, crimp grounding connector 

and blade terminal, S#2 Insert gland bracket, grounding connector, and associated seals to red and black 

wire subassemblies, S#3 strip insulator @ core and shield, crimp on ground connectors, snap in gland 

bracket, S#4 crimp eyelet terminals, and load on pre-shrink tube insulators, heat distort into position, S#5 

press grounding sockets onto grounding plugs (blade ends) and press both ends into main conneector, 

snap connector covers into position S#6 install convolute and tape onto wire harness assembly, S#7 snap 

x-tree locator into position, inspect and pack. 

3 2 10 60 47 2820 160 22.56 85% 188 19.18 - 8 1 20 8.0 1.0 180 20.00 8.00

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

1A Copper Cable 120301-N0602-450

2A Eyelet Termials 120301-N0602-451

2B Grounding Connector Stamped Sub 120301-N0602-452

2C ID Connector Seal (Orange) 120301-N0602-453

2D OD Connector Seal (Black) 120301-N0602-454

2E Shrink Wrap Terminal Lead 120301-N0602-455

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 1 2 10 20 47 940 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$6.40

$0.10

$0.50

$0.05

$0.05

$0.02

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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.

2F Die Cast Gland Bracket 120301-N0602-456

3A Blade Terminal 120301-N0602-457

3B Grounding Connector Crimp 120301-N0602-458

3C Grounding Connector Socket 120301-N0602-459

3D ID Connector Seal 120301-N0602-460

3E Connector Rear Cap 120301-N0602-461

3F Terminal Lock Tab 120301-N0602-462

3G Connector - AC Compressor to Main 120301-N0602-463

3H Shorting Key 120301-N0602-464

4A Orange Convolute Wrap (Split) 120301-N0602-465

5A Tape Convolute Wrap 120301-N0602-466

6A Wire Harness X-mas tree snap 120301-N0602-466

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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

$0.50

$0.16

$0.20

$0.40

$0.06

$0.10

$0.04

$0.24

$0.01

$0.14

$0.06

6A Wire Harness X-mas tree snap 120301-N0602-466 $0.08

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$1.71 $0.67 $11.48 $0.00 $0.00 $0.00 $0.00 $0.00

$11.48

2

Notes: 

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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: 1 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

1 1A H Seal, Spiral Scroll (Fixed Scroll) 120301-N0602-900 1 Injection Mold T2/T3 Inject. Mold, SSLC Thermoset-Vespel SP21CF30 Mold/Cast/Sinter Operator Inject. Mold, SS 1500 0.25 1 1.1 0.005 $35.18 $41.48 $16.39 $18.03 $0.17 $0.01 $0.01 $0.19 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.21 $0.21 $0.17

2 2A H Seal, Spiral Scroll (Moving Scroll) 120301-N0602-901 1 Injection Mold T2/T3 Inject. Mold, SSLC Thermoset-Vespel SP21CF30 Mold/Cast/Sinter Operator Inject. Mold, SS 1500 0.25 1 1.1 0.005 $35.18 $41.48 $16.39 $18.03 $0.17 $0.01 $0.01 $0.19 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.21 $0.21 $0.17

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 3A H Check Valve Support, Scroll Valve 120301-N0602-902 1 Stamping T1 Assembly, Mark-up Applied 

@ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, XSS 571 0.5 1 2 0.083 $0.45 $42.73 $24.60 $49.20 $0.04 $0.04 $0.09 $0.16 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.16 $0.16 $0.04

T1 Assembly, Mark-up Applied 

Costs Broken Out In

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

5 4A H Check Valve, Rear Scroll 120301-N0602-903 1 Stamping T1 Assembly, Mark-up Applied 

@ Bottom. SPR-Steel, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals 571 0.5 1 2 0.006 $0.65 $42.73 $15.50 $31.00 $0.004 $0.04 $0.05 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.10 $0.10 $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 5A H Restrictor, Rear Scroll, Oil 120301-N0602-904 1 CNC Turning T1 Assembly, Mark-up Applied 

@ Bottom. MC-Steel-1018, Bar Lathe/Turning Operator DS-CNC Turning, SS, BF, DA 129 0.5 1 1 0.011 $0.74 $38.97 $25.52 $25.52 $0.01 $0.15 $0.20 $0.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.36 $0.36 $0.01

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 6A H Balance, AC Pump Crank, 120301-N0602-905-03 1 Fine Blank T2/T3 Stamp/Form, SSLC MC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, XSS 275 0.5 1 3 0.600 $0.55 $42.73 $24.60 $73.80 $0.33 $0.08 $0.27 $0.68 0.30% 6.00% 4.00% 0.00% 10.30% $0.07 $0.75 $0.75 $0.33

10 6B H Balance, AC Pump Crank, 120301-N0602-905-02 1 Machine T2/T3 CNC Milling, SSLC Not Applicable CNC Operator CNC Machining, LC 100 1 1 1 0.000 $0.00 $36.98 $30.38 $30.38 $0.00 $0.37 $0.30 $0.67 0.30% 6.00% 4.00% 0.00% 10.30% $0.07 $0.74 $0.74 $0.00

11 6C H Balance, AC Pump Crank, 120301-N0602-905-01 1 Fine Blank T2/T3 CNC Milling, SSLC Not Applicable CNC Operator Washing Equipment, LC 3600 0.25 1 1 0.000 $0.00 $36.98 $10.75 $10.75 $0.00 $0.00 $0.003 $0.01 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.01 $0.01 $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 7A H Shaft, AC Pump Crank, Washed 120301-N0602-906-03 1 Machine T1 Assembly, Mark-up Applied 

@ Bottom. A-Steel-4140, Bar 0.25-1" CNC Operator DS-CNC Turning, SS, BF, DA 129 0.5 1.5 1 0.200 $1.23 $36.98 $25.52 $38.28 $0.25 $0.14 $0.30 $0.69 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.69 $0.69 $0.25

14 7B H Shaft, AC Pump Crank, Washed 120301-N0602-906-02 1 Washed T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable CNC Operator Washing Equipment, LC 225 0 1 1 0.000 $0.00 $36.98 $10.75 $10.75 $0.00 $0.00 $0.05 $0.05 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.05 $0.05 $0.00

15 7C H Shaft, AC Pump Crank, Washed 120301-N0602-906-01 1 Case Harden T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Heat Treat Operator Nitriding - Case Harden 563 1 1 1 0.000 $0.00 $47.72 $100.00 $100.00 $0.00 $0.08 $0.18 $0.26 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.26 $0.26 $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 8A H Shaft, AC Pump Crank, Pin 120301-N0602-907-03 1 Machine T1 Assembly, Mark-up Applied 

@ Bottom. A-Steel-4140, Bar 0.25-1" CNC Operator DS-CNC Turning, SS, BF, DA 327 0.5 1 1 0.010 $1.23 $36.98 $25.52 $25.52 $0.01 $0.06 $0.08 $0.15 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.15 $0.15 $0.01

18 8B H Shaft, AC Pump Crank, Pin 120301-N0602-907-02 1 Washed T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable CNC Operator Washing Equipment, LC 360 0 1 1 0.000 $0.00 $36.98 $10.75 $10.75 $0.00 $0.00 $0.03 $0.03 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.03 $0.03 $0.00

19 8C H Shaft, AC Pump Crank, Pin 120301-N0602-907-01 1 Case Harden T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Heat Treat Operator Nitriding - Case Harden 563 1 1 1 0.000 $0.00 $47.72 $100.00 $100.00 $0.00 $0.08 $0.18 $0.26 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.26 $0.26 $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 9A H Gasket, AC Pump 120301-N0602-907-03 1 Stamping & wash T2/T3 Stamp/Form, SSLC SPR-Steel, Coil Cut/Punch/Forming Operator Stamp/Form, XSS 462 0.25 1 1.1 0.089 $0.65 $42.73 $24.60 $27.06 $0.06 $0.02 $0.06 $0.14 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.15 $0.15 $0.06

22 9B H Gasket, AC Pump 120301-N0602-907-02 1 Grind Flat T2/T3 Stamp/Form, SSLC Not Applicable Cut/Punch/Forming Operator Flat Stock Grind-Polish, SS 1200 0.25 1 1 0.000 $0.00 $42.73 $35.00 $35.00 $0.00 $0.01 $0.03 $0.04 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.04 $0.04 $0.00

23 9C H Gasket, AC Pump 120301-N0602-907-01 1

Phosphate Pre-coat, Anti 

Friction Coating single side T2/T3 Plate/Finish Mech., SSLC High Temp, Anti Friction, PTFE Coating Plating/Coating Operator Anti Friction Plating, FP, SS 240 3 1 1 0.001 $178.57 $40.84 $175.00 $175.00 $0.11 $0.51 $0.73 $1.35 0.30% 6.00% 4.00% 0.00% 10.30% $0.14 $1.49 $1.49 $0.11

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 10A H Pump Transfer Guide 120301-N0602-908-01 1 Press & Sinter T2/T3 Powder Metal, SSLC PM-SMF-FC0208 Mold/Cast/Sinter Operator Powder Metal, LMC 154 1 1 1 0.000 $1.00 $41.48 $100.00 $100.00 $0.00 $0.27 $0.65 $0.92 0.30% 6.00% 4.00% 0.00% 10.30% $0.09 $1.01 $1.01 $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 11A H Cover, Housing Compressor 120301-N0602-909-03 1 Stamping T2/T3 Stamp/Form, SSLC Metal Laminate, Type A, < 1.0 Cut/Punch/Forming Operator Stamp/Form, XSS 1385 0.25 1 1 0.404 $0.80 $42.73 $24.60 $24.60 $0.32 $0.01 $0.02 $0.35 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.38 $0.38 $0.32

28 11B H Cover, Housing Compressor 120301-N0602-909-02 1 Power Coat T2/T3 Plate/Finish Mech., 

MSMC Acrylic Powder Coat Plating/Coating Operator Powder Coat, LC 240 1 1 1 0.030 $20.00 $40.84 $100.00 $100.00 $0.59 $0.17 $0.42 $1.18 0.50% 6.50% 6.00% 1.00% 14.00% $0.17 $1.35 $1.35 $0.59

29 11C H Cover, Housing Compressor 120301-N0602-909-01 1 EMI Coat, speak with Sheila T T2/T3 Plate/Finish Mech., 

MSMC Powder Coat Plating/Coating Operator Powder Coat, LC 240 1 1 1 0.030 $20.00 $40.84 $100.00 $100.00 $0.59 $0.17 $0.42 $1.18 0.50% 6.50% 6.00% 1.00% 14.00% $0.17 $1.35 $1.35 $0.59

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

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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

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

"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.

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

Material

$2.66

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

Mark-up $9.75

T1 or OEM Total Manufacturing Cost: $2.66 $2.22 $4.06 $8.95 $0.03 $0.43 $0.32 $0.02 $0.80 $9.75

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 $0.63 $0.58 $0.24 $1.51

Base Cost Impact to Vehicle: $2.66 $2.22 $4.06 $8.95 $0.07 $1.06 $0.91 $0.27 $2.31 $11.26 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $11.26

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

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

3

1

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

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

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

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

S. 020909)

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) Piece Price Per Pallet/Rack Price Per Pallet/Rack Price Per Pallet/Rack Price Per Pallet/Rack Price Per 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

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

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

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

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

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

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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)

Purchase Part - High Impact Item (Full Cost Mapping)

1A H Seal, Spiral Scroll (Fixed Scroll) 120301-N0602-900

2A H Seal, Spiral Scroll (Moving Scroll) 120301-N0602-901

3A H Check Valve Support, Scroll Valve 120301-N0602-902

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

$0.01 $0.01 $0.19 $0.00 $0.01 $0.01 $0.00 $0.02 Injection Mold, 4 Cavity 1 2 10 20 47 940 479 7.52 85% 563 6.39 9.60 1 4 10 1.1 1.0 1500 2.40 0.25

$0.01 $0.01 $0.19 $0.00 $0.01 $0.01 $0.00 $0.02 Injection Mold, 4 Cavity 1 2 10 20 47 940 479 7.52 85% 563 6.39 9.60 1 4 10 1.1 1.0 1500 2.40 0.25

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

$0.04 $0.09 $0.16 $0.00 $0.00 $0.00 $0.00 $0.00 Progressiive Die, Single part per hit, tumble & wash 1 2 10 20 47 940 479 7.52 85% 563 6.39 6.3 3 1 6.3 2.0 1.0 571 6.30 0.50

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

4A H Check Valve, Rear Scroll 120301-N0602-903

5A H Restrictor, Rear Scroll, Oil 120301-N0602-904

6A H Balance, AC Pump Crank, 120301-N0602-905-03

6B H Balance, AC Pump Crank, 120301-N0602-905-02

6C H Balance, AC Pump Crank, 120301-N0602-905-01

7A H Shaft, AC Pump Crank, Washed 120301-N0602-906-03

7B H Shaft, AC Pump Crank, Washed 120301-N0602-906-02

7C H Shaft, AC Pump Crank, Washed 120301-N0602-906-01

8A H Shaft, AC Pump Crank, Pin 120301-N0602-907-03

8B H Shaft, AC Pump Crank, Pin 120301-N0602-907-02

8C H Shaft, AC Pump Crank, Pin 120301-N0602-907-01

9A H Gasket, AC Pump 120301-N0602-907-03

9B H Gasket, AC Pump 120301-N0602-907-02

9C H Gasket, AC Pump 120301-N0602-907-01

10A H Pump Transfer Guide 120301-N0602-908-01

$0.04 $0.05 $0.10 $0.00 $0.00 $0.00 $0.00 $0.00 Progressiive Die, Single part per hit, tumble & wash 1 2 10 20 47 940 479 7.52 85% 563 6.39 6.3 3 1 6.3 2.0 1.0 571 6.30 0.50

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

$0.15 $0.20 $0.36 $0.00 $0.00 $0.00 $0.00 $0.00 CNC Turning Machine, Single Station 5 2 10 100 47 4700 96 37.60 85% 113 31.96 28 1 1 28 1.0 1.0 129 28.00 0.50

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

$0.08 $0.27 $0.68 $0.00 $0.04 $0.03 $0.00 $0.07 1 Off ,Fine Blank Tool (x3 stamping rate) 2 2 10 40 47 1880 239 15.04 85% 282 12.78 7.6 3 1 13.07 3.0 1.0 275 13.07 0.50

$0.37 $0.30 $0.67 $0.00 $0.04 $0.03 $0.00 $0.07 4 Axis CNC, multi part fixture, operator load and unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 36.0 1 1 36.00 1.0 1.0 100 36.00 1.00

$0.00 $0.00 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 Batch wash 2 2 10 40 47 1880 239 15.04 85% 282 12.78 16.0 1 16 16.00 1.0 1.0 3600 1.00 0.25

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

$0.14 $0.30 $0.69 $0.00 $0.00 $0.00 $0.00 $0.00 CNC Turning, Double Sided part, 1.5 Machines 5 2 10 100 47 4700 96 37.60 85% 113 31.96 42 1 1 42 1.0 1.5 129 28.00 0.50

$0.00 $0.05 $0.05 $0.00 $0.00 $0.00 $0.00 $0.00 Batch wash 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 1 1 16 1.0 1.0 225 16.00 -

$0.08 $0.18 $0.26 $0.00 $0.00 $0.00 $0.00 $0.00 Nitride 24 Hours @ Approx 600°C, Batches of 13500 Parts 1 2 10 20 47 940 479 7.52 85% 563 6.39 - 1 13,500 86,400 1.0 1.0 563 6.40 1.00

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

$0.06 $0.08 $0.15 $0.00 $0.00 $0.00 $0.00 $0.00 CNC Turning, Double Sided part, 1.0 Machine 2 2 10 40 47 1880 239 15.04 85% 282 12.78 11 1 1 11 1.0 1.0 327 11.00 0.50

$0.00 $0.03 $0.03 $0.00 $0.00 $0.00 $0.00 $0.00 Batch wash 2 2 10 40 47 1880 239 15.04 85% 282 12.78 10 1 1 10 1.0 1.0 360 10.00 -

$0.08 $0.18 $0.26 $0.00 $0.00 $0.00 $0.00 $0.00 Nitride 24 Hours @ Approx 600°C, Batches of 13500 Parts 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 13,500 86,400 1.0 1.0 563 6.40 1.00

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

$0.02 $0.06 $0.14 $0.00 $0.01 $0.01 $0.00 $0.01 Progressive Die includes secondary batch wash 1.5 2 10 30 47 1410 319 11.28 85% 375 9.59 7.8 1 1 7.8 1.1 1.0 462 7.80 0.25

$0.01 $0.03 $0.04 $0.00 $0.00 $0.00 $0.00 $0.00 Auto vibratory fed, single station grinding 1 2 10 20 47 940 479 7.52 85% 563 6.39 - 1 1 3 1.0 1.0 1200 3.00 0.25

$0.51 $0.73 $1.35 $0.00 $0.08 $0.05 $0.00 $0.14 Anit firction application line( wash, rinse, phosphate undercoat, anti friction spray coat, cure) 2.5 2 10 50 47 2350 191 18.80 85% 225 15.98 - 1 1 15 1.0 1.0 240 15.00 3.00

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

$0.27 $0.65 $0.92 $0.00 $0.06 $0.04 $0.00 $0.09 50 Ton powder metal compaction press with in-line sintering furnace. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 23.4 1 1 23.4 1.0 1.0 154 23.40 1.00

11A H Cover, Housing Compressor 120301-N0602-909-03

11B H Cover, Housing Compressor 120301-N0602-909-02

11C H Cover, Housing Compressor 120301-N0602-909-01

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

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

$0.01 $0.02 $0.35 $0.00 $0.02 $0.01 $0.00 $0.04 Progressive Die 1 2 10 20 47 940 479 7.52 85% 563 6.39 0.60 1 1 2.6 1.0 1.0 1385 2.60 0.25

$0.17 $0.42 $1.18 $0.01 $0.08 $0.07 $0.01 $0.17 Powder Coat Assembly Line, Single Operator load/unload, Clean, Spray Coat, Cure 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 3 1 15 1.0 1.0 240 15.00 1.00

$0.17 $0.42 $1.18 $0.01 $0.08 $0.07 $0.01 $0.17 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 3 1 15 1.0 1.0 240 15.00 1.00

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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

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

Total

$2.22 $4.06 $8.95 $0.03 $0.43 $0.32 $0.02 $0.80

$9.75

2

Notes: 

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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: 1 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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 

Mark-up 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

1 1A H Scroll Housing Subassembly Build-Up 120301-N0602-025 1

Assembly rear scroll and 

associated hardware to H Scroll 

Housing

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 200 2 1 8 0.000 $0.00 $38.55 $30.00 $240.00 $0.00 $0.39 $1.20 $1.59 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.59 $1.59 $0.00

2 1B Mid Plate & Motor Rotor Build-up 120301-N0602-026 1

Assembly Motor Rotor to Mid 

Plate Subassembly

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, MHC, Base 200 1 1 5 0.000 $0.00 $38.55 $37.50 $187.50 $0.00 $0.19 $0.94 $1.13 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.13 $1.13 $0.00

3 1C H Balance, AC Pump Crank Subassembly 120301-N0602-027 1 Counter Balance Subassembly build-up T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LMC, Base 200 2 1 1 0.000 $0.00 $38.55 $22.50 $22.50 $0.00 $0.39 $0.11 $0.50 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.50 $0.50 $0.00

4 1D Scroll Subassembly 120301-N0602-028 1

Press Needle bearing and add 

scroll seal 

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 200 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.19 $0.08 $0.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.27 $0.27 $0.00

5 1E Mechanical Compressor Final Assembly 120301-N0602-029 1

Complete assembly of Motor 

and Scroll Subassembly

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, MHC, Base 200 3 1 9 0.000 $0.00 $38.55 $37.50 $337.50 $0.00 $0.58 $1.69 $2.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.27 $2.27 $0.00

Costs Broken Out 

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Cos

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc. 47 North America

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

and Scroll Subassembly @ Bottom.

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 2A Electronic & Final Assembly of AC Compressor 120301-N0602-035 1

Electronic & Final Assembly of 

AC Compressor

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, MHC, Base 200 8 1 16 0.000 $0.00 $38.55 $37.50 $600.00 $0.00 $1.54 $3.00 $4.54 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $4.54 $4.54 $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

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

1 0 ##### 0 1 1.1 0.617 #N/A #N/A #N/A #N/A #N/A #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

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 1A H Bearing, Needle Impeller 120301-N0602-050 1 Pressed into scroll S $0.00 $0.64 $0.00 $0.64 $0.64

2 2A H Stud, Rear Scroll (Inlet & Outlet Tubes) 120301-N0602-051 2 S $0.00 $0.04 $0.00 $0.08 $0.08

3 3A H Nut, To Stud, Rear Scroll 120301-N0602-052 2

Would be purchase part @ $0.00 $0.04 $0.08 $0.00 $0.00

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

3 3A H Nut, To Stud, Rear Scroll 120301-N0602-052 2

Would be purchase part @ 

assembly plant $0.00 $0.04 $0.08 $0.00 $0.00

4 4A H O-ring, Rear Scroll, Pressure Relief 120301-N0602-053 1 S $0.00 $0.04 $0.00 $0.04 $0.04

5 4B H Pressure Relief, Rear Scroll 120301-N0602-054 1 S $0.00 $0.25 $0.00 $0.25 $0.25

6 5A H O-ring, Large Plug 120301-N0602-055 1 S $0.00 $0.04 $0.00 $0.04 $0.04

7 5B H Plug, Large, Rear Scroll 120301-N0602-056 1 S $0.00 $0.18 $0.00 $0.18 $0.18

8 6A H Bolt, Scroll Valve, M6 x 12 120301-N0602-057 1 S $0.00 $0.02 $0.00 $0.02 $0.02

9 7A H Filter Screen, Rear Scroll Oil 120301-N0602-058 1 S $0.00 $0.10 $0.00 $0.10 $0.10

10 8A H O-ring, Rear Scroll 120301-N0602-059 1 S $0.00 $0.06 $0.00 $0.06 $0.06

11 9A H Spacer, Scroll Housing 120301-N0602-060 1 S $0.00 $2.50 $0.00 $2.50 $2.50

12 10A H O-ring, Bolt, Scroll Impeller 120301-N0602-061 3 S $0.00 $0.03 $0.00 $0.09 $0.09

13 11A H Bolt, Scroll Housing Impeller 120301-N0602-062 3 S $0.00 $0.05 $0.00 $0.15 $0.15

"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.

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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 

Mark-up 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out 

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Cos

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc. 47 North America

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

14 12A H Bolt, Scroll Housing 120301-N0602-063 4 S $0.00 $0.07 $0.00 $0.28 $0.28

15 13A H O-ring Inner, AC Compressor 120301-N0602-064 2 S $0.00 $0.05 $0.00 $0.10 $0.10

16 14A H O-ring Outer, AC Compressor 120301-N0602-065 2 S $0.00 $0.05 $0.00 $0.10 $0.10

17 15A H Bearing, AC Pump 120301-N0602-066 1 S $0.00 $2.43 $0.00 $2.43 $2.43

18 16A H Dowel Pin, Small, Midplate Asm 120301-N0602-067 2 S $0.00 $0.01 $0.00 $0.02 $0.02

19 17A H Dowel Pin, Midplate Asm 120301-N0602-068 2 S $0.00 $0.02 $0.00 $0.04 $0.04

20 18A H Rubber Bushing, On Post 120301-N0602-069 1 S $0.00 $0.03 $0.00 $0.03 $0.03

21 19A H Sticker, Warning, Compressor 120301-N0602-070 1 S $0.00 $0.05 $0.00 $0.05 $0.05

22 20A H Sticker, Informational, Compressor 120301-N0602-071 1 S $0.00 $0.05 $0.00 $0.05 $0.05

23 21A H Bearing, Needle Compressor Motor 120301-N0602-072 1 S $0.00 $0.30 $0.00 $0.30 $0.30

24 22A H Sticker, Hazardous, Info Compressor 120301-N0602-073 1 S $0.00 $0.05 $0.00 $0.05 $0.05

25 23A Electronic Grade Silicone 120301-N0602-074 1 Approx. 2 oz S $0.00 $1.64 $0.00 $1.64 $1.64

26 24A Shoulder Bolt - Terminal Interface Assembly 120301-N0602-075 1 S $0.00 $0.15 $0.00 $0.15 $0.15

27 25A Bolt - Terminal Interface 120301-N0602-076 2 S $0.00 $0.03 $0.00 $0.06 $0.06

28 26A Bolt - Electronic Board Interface to Housing 120301-N0602-077 7 S $0.00 $0.02 $0.00 $0.11 $0.11

29 27A Silicone - Housing Cover 120301-N0602-78 1 S $0.00 $0.11 $0.00 $0.11 $0.11

30 28A Bolt - Cover 120301-N0602-79 11 S $0.00 $0.02 $0.00 $0.22 $0.22

31 29A Potting Gel Potting Gel 120301-N0602-80 120301-N0602-80 1 S $0.00 $8.64 $0.00 $8.64 $330,000 $330,000 $8.64

32 30A Studs inlet and outlet fitting line 120301-N0602-81 2 S $0.00 $0.08 $0.00 $0.16 $0.16

Material

$9.88

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

Mark-up $20.17

T1 or OEM Total Manufacturing Cost: $9.88 $3.28 $7.01 $20.17 $0.00 $0.00 $0.00 $0.00 $0.00 $20.17

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 ----- ----- ----- $0.10 $1.31 $1.21 $0.50 $3.13

Base Cost Impact to Vehicle: $9.88 $3.28 $7.01 $20.17 $0.10 $1.31 $1.21 $0.50 $3.13 $23.30 $330,000 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $23.30

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

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

3

1

Notes: 

a) Items 1,2, & 3 mus

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 Returnables Last 5 Years

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

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

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

Package: 7 Layers of 6 on single Pallet Base.

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

Packaging Cost Total: $0.000

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

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

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

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

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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 

Mark-up 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out 

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

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Cos

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc. 47 North America

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level:

Reference #

Part Description Part Number

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

1A H Scroll Housing Subassembly Build-Up 120301-N0602-025

1B Mid Plate & Motor Rotor Build-up 120301-N0602-026

1C H Balance, AC Pump Crank Subassembly 120301-N0602-027

1D Scroll Subassembly 120301-N0602-028

1E Mechanical Compressor Final Assembly 120301-N0602-029

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

$0.39 $1.20 $1.59 $0.00 $0.00 $0.00 $0.00 $0.00

Automated linear subassembly line feeding final assembly line. Station #1 Manual install o-ring & scroll 

thrust seal to rear scroll, load rear scroll and housing to pallet, S#2 Manual load check value, hand start 

check valve bolt, S#3 Auto run down bolt, and insert oil restrictor and filter screen, S#4 Auto placement of 

rear scroll gasket and reposition scroll housing over rear scroll, S#5 auto placement of bolt o-rings, 

rundown of three rear scroll attachments, S#7 Auto run-down outer thread check valve, outlet port plug and 

outlet fitting stud, S#8 auto load scroll housing subassembly into buffer station.

5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 8 1 18 8.0 1.0 200 18.00 2.00

$0.19 $0.94 $1.13 $0.00 $0.00 $0.00 $0.00 $0.00

Automated linear subassembly line feeding final assembly line. S#1 Auto load mid plate and motor rotor to 

pallet, S#2 Auto press bearing onto motor rotor, S#3 press dowel pins into Mid plate, S#4 Auto press 

Motor Rotor Bearing Assembly into midplate, S#5 auto load motor rotor /mid plate subassembly into buffer 

station.

5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 5 1 18 5.0 1.0 200 18.00 1.00

$0.39 $0.11 $0.50 $0.00 $0.00 $0.00 $0.00 $0.00 Semi automated, 2 station work cell feeding main assembly line. S#1 Manual load balance crank and 

shaft, auto press, (gravity fed transfer) S#2 Manual load, auto press pin, manual install rubber isolator. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 2 1 18 1.0 1.0 200 18.00 2.00

$0.19 $0.08 $0.27 $0.00 $0.00 $0.00 $0.00 $0.00 Stand alone work cell and build of scroll subassembly, Manual load bearing and auto press into place , 

add scroll seal and pack. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 2 1 18 1.0 1.0 200 18.00 1.00

$0.58 $1.69 $2.27 $0.00 $0.00 $0.00 $0.00 $0.00

Automated linear transfer line, S#1 Manual Load Housing Compressor Motor, Scroll Subassembly and H 

Balance, AC Pump Crank Subassembly onto Pallet, S#2 Auto load and press Motor Rotor Bearing, 

Midplate Mounting Dowel Pins and run inlet mouting stud S#3 Auto Load and Press Motor Stator 

Assembly, S#4 Manual feed Motor Stator Wires into pass through window, load 2 O-rings, add Hazardous 

sticker to size of housing, S#5 Auto load and press Motor Rotor/Midplate Subassembly into compressor 

housing, S#6 Manual Assemble H Balance AC Pump Subassembly and press E-Clip into position, load 

5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 8 1 18 9.0 1.0 200 18.00 3.00

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

2A Electronic & Final Assembly of AC Compressor 120301-N0602-035

Purchase Part - High Impact Item (Full Cost Mapping)

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

1A H Bearing, Needle Impeller 120301-N0602-050

2A H Stud, Rear Scroll (Inlet & Outlet Tubes) 120301-N0602-051

3A H Nut, To Stud, Rear Scroll 120301-N0602-052

housing, S#6 Manual Assemble H Balance AC Pump Subassembly and press E-Clip into position, load 

inner and outer O-rings, S#7 Auto load and position Gasket, Transfer Guide and Scroll, S#8 Auto load 

Scroll Housing Subassembly onto Main Compressor/Midplate Housing Subassembly and rundown four 

fasteners. S#9 Automated unload to buffer line

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

$1.54 $3.00 $4.54 $0.00 $0.00 $0.00 $0.00 $0.00

Semi Automated Final Assembly Line S#1 Manually load Mechanical Compressor Subassembly to pallet, 

connect Motor Stator leads to Terminal Block Pass Thru Subassembly, hand start fasteners, S#2 Auto 

rundown terminal block pass thru, fill coil and capacitor chamber with Electronics Grade Silicone, S#3 

Manually crimp small coil to terminal block assembly, install coil/terminal block subassembly, large coil, 

and capacitor large into silicone, manual rundown terminal block fastener, S#4 Manual load Electronic 

board #2, auto rundown 3 fasteners, S#5 Auto install and run-down terminal interface shoulder bolt, 

position terminal interface assembly, run-down one place. S#6 Auto solder weld terminal interface 

assembly, 7 locations, S#7 Manually manipulate coil wires into terminal block interface assemble and 

crimp 4 locations, S#8 Manually make connection between Board #1 and Board #2, locate Board #1 into 

position. S#9 Auto rundown of board #2 (4 Plcs), S#10 Auto point solder board #1 connection (connection 

between board #1 and #2 ) .... (continued below)

5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 16 1 18 16.0 1.0 200 18.00 8.00

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

S#12 Manually install high voltage wire harness assembly, semi automated rundown 4 places, S#13 Auto 

apply RTV to housing perimeter, S#14 Auto load cover and rundown, (8Plcs),S#13, Auto filling station, 

potting Gel. + add seal following fill completion. S14# Manual load connector mount bracket/potting gel 

seal, semi automated run down, S #15/16 Auto Functional Test, Date Code and pack. (x1M)

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

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

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

$0.00 $0.00 $0.00 $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 #DIV/0! #DIV/0! -

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

$0.64

$0.08

3A H Nut, To Stud, Rear Scroll 120301-N0602-052 $0.00

4A H O-ring, Rear Scroll, Pressure Relief 120301-N0602-053

4B H Pressure Relief, Rear Scroll 120301-N0602-054

5A H O-ring, Large Plug 120301-N0602-055

5B H Plug, Large, Rear Scroll 120301-N0602-056

6A H Bolt, Scroll Valve, M6 x 12 120301-N0602-057

7A H Filter Screen, Rear Scroll Oil 120301-N0602-058

8A H O-ring, Rear Scroll 120301-N0602-059

9A H Spacer, Scroll Housing 120301-N0602-060

10A H O-ring, Bolt, Scroll Impeller 120301-N0602-061

11A H Bolt, Scroll Housing Impeller 120301-N0602-062

$0.00

$0.04

$0.25

$0.04

$0.18

$0.02

$0.10

$0.06

$2.50

$0.09

$0.15

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology 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.

12A H Bolt, Scroll Housing 120301-N0602-063

13A H O-ring Inner, AC Compressor 120301-N0602-064

14A H O-ring Outer, AC Compressor 120301-N0602-065

15A H Bearing, AC Pump 120301-N0602-066

16A H Dowel Pin, Small, Midplate Asm 120301-N0602-067

17A H Dowel Pin, Midplate Asm 120301-N0602-068

18A H Rubber Bushing, On Post 120301-N0602-069

19A H Sticker, Warning, Compressor 120301-N0602-070

20A H Sticker, Informational, Compressor 120301-N0602-071

21A H Bearing, Needle Compressor Motor 120301-N0602-072

22A H Sticker, Hazardous, Info Compressor 120301-N0602-073

23A Electronic Grade Silicone 120301-N0602-074

24A Shoulder Bolt - Terminal Interface Assembly 120301-N0602-075

25A Bolt - Terminal Interface 120301-N0602-076

26A Bolt - Electronic Board Interface to Housing 120301-N0602-077

27A Silicone - Housing Cover 120301-N0602-78

28A Bolt - Cover 120301-N0602-79

29A Potting Gel 120301-N0602-80

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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

$0.28

$0.10

$0.10

$2.43

$0.02

$0.04

$0.03

$0.05

$0.05

$0.30

$0.05

$1.64

$0.15

$0.06

$0.11

$0.11

$0.22

29A Potting Gel 120301-N0602-80 $8.64

30A Studs inlet and outlet fitting line 120301-N0602-81

$8.64

$0.16

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

Total

$3.28 $7.01 $20.17 $0.00 $0.00 $0.00 $0.00 $0.00

$20.17

2

Notes: 

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 6 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology 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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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
Symbol Name

0

H Bracket AC Compressor 

Mount to Block

1 H Bracket AC Compressor 

Deburred

2 H Bracket AC Compressor 

Machined

3 H Bracket AC Compressor 

Casting Trimmed

4 H Bracket AC Compressor 

Casting

5 H Bracket Compressor 

Material

0 H Bolt AC Compressor Bracket

0 H Electric AC Compressor 

Assembly

1 H Housing, Coil, and 

Electronics Asm.

2 H Housing Asm., Potted 

Electronics

3 H Housing, Compressor 

Motor, Washed, Final Part
Level Symbol Name

4 H Housing, Compressor 

Motor, Machined

5 H Housing, Compressor 

Motor, Trimmed

6

7

3 H Bearing, Needle, 

Compressor Motor

3 H Gasket, Terminal 

Passthrough

4 H Gasket, Terminal 

Passthrough

3 H Terminal Block, 

Passthrough Asm.

4 H Plate Terminal Block, 

Passthrough Asm

5 H Plate Terminal Block, 

Passthrough Asm

4 H Leads Terminal Block, 

Passthrough Asm

3 H Bolt, Terminal Block 

Passthrough

3 H Inductor Asm, Coil, Large
3 H Inductor Asm, Coil, Small

3 H Capacitor, Large

3 H Terminal Block Asm.

3 H Terminal Interface Assembly

3 H AC PCB 1 preassembled

4 H AC PCB 1 w all 

components

5 H AC PCB 1 w Thru Hole 

mntd

6

7

7

Level
Level

7
6

6

3 H Bracket AC PCB 

1connector

Level Symbol Name

4 H Bracket AC PCB 

1connector-Blank

3 H Screw IGBT to base

3 H AC PCB 2 preassembled

4 H AC PCB 2 wo metal base

5 H AC PCB 2 w all 

components
6

7

Level
7

7

7

4 H AC PCB 2 Base plate assy

5 H AC PCB 2 Base plate 

assy-Washing

6

Level

7

4 IC IGBT - Screw Attachment

4 H Screw IGBT to base

4 H screw AC PCB 2 wire lead

3 H Screw IGBT to base

2 H Cover Assembly
3 H Cover Compressor 

Housing

4 H Cover Compressor Housing

3 H Sticker, Warning, 

Compressor

3 H Sticker, Informational, 

Compressor

2 H Screw IGBT to base

1 H O-ring, Outer, AC 

Compressor

1 H O-ring, Inner, AC 

Compressor

1 H AC Compressor Motor 

Stator Asm

2 H AC Motor Stator Stack, 

Machined

3 H AC Motor Stator Stack

Level Symbol Name

4 H AC Motor Stator Plates - 

w/Alignment Notch & Hol

5 H AC Motor Stator Plates - w/ 

Notch & Holes Materi

4 H AC Motor Stator Plates - 

w/1 Notch no holes

5 H AC Motor Stator Plates - 

w/Notch & No Holes Mate
4 H AC Motor Stator Plates - 

No Notch

5 H AC Motor Stator Plates - No 

Notch Material

4 H AC Motor Stator Plates - 3 

notches - no holes

5 H AC Motor Stator Plates, 3 

notches, no holes - ma

4 H AC Motor Stator Plates - 3 

notches plus holes

5 H AC Motor Stator Plates - w/3 

Notche & Holes Mate

2 H AC Motor Stator Insulator 

Base

Level Symbol Name

3 H AC Motor Stator Base 

Material

2 H AC Motor Stator Insulator 

Top

3 H AC Motor Stator Top 

Material

2 H AC Motor Stator Insulator 

Liners

2 H AC Motor Stator Windings

2 H AC Motor Stator Green 
Terminal with 3/wires

2 H AC Motor Stator Red 

Terminal with 3/wires

2 H AC Motor Stator Black 

Terminal with 3/wires

2 H AC Motor Stator Insulator 

Film

2 H AC Tie Wrap

2 H AC Motor Stator Winding 

Spacers

1 H AC Motor Stator Wire 

Retainer Cap

2 H AC Motor Stator Retainer 

Material

1 H Scroll Impeller Asm.

Level Symbol Name

2 H AC Motor Magnets and 

Shaft Asm.

3 H AC Motor Shaft

4 H AC Motor Shaft, Machined

5 H AC Motor Shaft, Material

3 H AC Motor Rotor Asm, 

Riveted

4 H AC Motor Rivets

4 H AC Motor Weight #1
5 AC Motor Weight #1 

Deburred

6

7

4 H AC Motor Rotor Endplate 

#1

5 H AC Motor Rotor Endplate 

#1 Stamped

6

4 H Ac Motor Rotor Plate Asm

5 H AC Motor Rotor Plate

Level

6

4 H AC Motor Magnets

4 H AC Motor Rotor Endplate 

#2

5 H AC Motor Rotor Endplate 

#2 Stamped

6

4 H AC Motor Weight #2
5 AC Motor Weight #2 

Deburred

6

7

2 H Midplate Asm.

3 H Midplate, Washed

4 H Midplate, Deburred

5 H Midplate, Machined

6

7

Level Symbol Name

3 H Bearing, AC Pump

3 H Dowel Pin, Midplate Asm.

3 H Dowel Pin, Small, Midplate 

Asm

2 H AC Pump, Crank Asm.

3 H Shaft, AC Pump Crank, 

Asm

4 H Shaft, AC Pump Crank, 

Washed

5 H Shaft, AC Pump Crank, 

Machined
6

4 H Shaft, AC Pump Crank, Pin

5 H Shaft, AC Pump Crank, 

Pin, Deburred

6

7

3 H Balance, AC Pump Crank, 

Washed

4 H Balance, AC Pump Crank - 

Deburred

5 H Balance, AC Pump Crank - 

Machined

Level

6

7

3 H Rubber Bushing, On Post

2 H Gasket, AC Pump

3 H Gasket, AC Pump Material

2 H Pump Transfer Guide
3 H Pump Transfer Guide 

Material

1 H O-ring, Outer, AC 

Compressor

1 H O-ring, Inner, AC 

Compressor

1 H Scroll Housing Asm.

2 H Rear Scroll Asm, Scroll 

Housing

3 H Rear Scroll

4 H Rear Scroll, Machined

5 H Rear Scroll, Trimmed

6

7

Level Symbol Name

3 H Check Valve, Rear Scroll

4 H Check Valve, Rear Scroll

5 H Check Valve, Rear Scroll, 

Stamped

6

3 H Check Valve Support, 

Scroll Valve

4 H Check Valve Support, 
Scroll Valve, Deburred

5 H Check Valve Support, 

Scroll Valve, Stamped

6

3 H Bolt, Scroll Valve, M6 x 12

3 H Restrictor, Rear Scroll, Oil 

Passage

4 H Restrictor, Rear Scroll, Oil 

Passage, Machined

5 H Restrictor, Rear Scroll, Oil 

Passage, Steel

Level Symbol Name

3 H Filter Screen, Rear Scroll, 

Oil Passage

3 H O-ring, Rear Scroll

3 H Seal, Spiral, Scroll

4 H Seal, Spiral, Scroll, Vespel

2 H Spacer, Scroll Housing, 

Painted

3 H Spacer, Scroll Housing, 

Washed

4 H Spacer, Scroll Housing, 

Stamped
5 H Spacer, Scroll Housing, 

MPM Material

2 H Scroll Housing

3 H Scroll Housing, Machined

4 H Scroll Housing, Trimmed

5 H Scroll Housing, Die Cast

6

2 H Bolt and O-ring Asm., 

Scroll Impellar

Level Symbol Name

3 H Bolt, Scroll Housing, Impellar

3 H O-ring, Bolt, Scroll Impellar

2 H Plug, Large, Rear Scroll, 

Asm.

3 H Plug, Large, Rear Scroll

3 H O-ring, Large Plug

2 H Pressure Relief Asm, Rear 

Scroll

3 H Pressure Relief, Rear Scroll

3 H O-ring, Rear Scroll, Pressure 

Relief
2 H Stud, Rear Scroll

2 H Nut, To Stud, Rear Scroll

2 H Impeller Scroll Asm, Scroll 

Housing

3 H ImpellerScroll

4 H Impeller Scroll, Anodize

5 H Impeller Scroll, Machined

6

7

Level

3 H Bearing, Needle, Impeller 

Scroll

3 H Seal, Spiral, Scroll

4 H Seal, Spiral, Scroll, Vespel

1 H Bolt, Scroll Housing, M8 x 40

0 H Bolt AC Compressor

Number

H Bracket AC 

Compressor 

Mount to 

Block

H Bracket AC 

Compressor 

Deburred

H Bracket AC 

Compressor 

Machined

t Compressor 

H Bolt AC 

Compressor 

Bracket

H Electric AC 

Compressor 

Assembly

H Housing, 

Coil, and 

Electronics 

Asm.

H Housing 

Asm., Potted 

Electronics
ng, Compressor 

H Housing, Compressor 

Motor, Casting

H Housing, Compressor Motor, 

Alum Mtl

erminal Block, 
B 1 w Thru Hole 

H AC PCB 1 w SMT mntd

H AC Board 1 Bare FR4

H AC board 1 BOTTOM SIDE

8 IC H8 MCU FLASH 256K 

100TQFP

8 IC - OP Amp

8 IC - Voltage Regulator

Symbol Name

8 IC - OPTOCOUPLER

8 IC - OPTOCOUPLER

8 IC - Optoisolators

8 IC - Transceiver

8 Diode
8 IC - Digital to Analog Converter

8 Zener Diode

8 IC - Bridge Rectifier

8 IC Unmarked

8 MOSFET

8 Chip Resistor - Surface Mount

8 Chip Resistor - Surface Mount

8 Inductor

8 Inductor

8 10000 KSS807F

8 MOSFET

8 Diode

8 Schottky Diode

8 Capacitors

8 Resistors

Symbol Name

H AC board 1 TOP SIDE - 

SURFACE MOUNT

8 Aluminum Capacitor - SM

8 Aluminum Capacitor - SM

8 Aluminum Capacitor - SM

8 Zener Diode - SM
8 Transistors (BJT) - SM

8 Zener Diode - SM

8 Diode

8 IC REG LDO 400MA 5.0V 

DPAK

8 Zener Diode

8 Schottky Diode

8 Transformer - SM

8 Schottky Diode

8 Capacitors

8 Resistors

Connector Asm - 8 position

Header - 22 position
H AC PCB 2 w thru hole 

mnted

H AC PCB 2 w SMT mnted

8 H AC Board 2 Bare FR4

8 H AC Board 2 BOTTOM SIDE 

- SURFACE MOUNT

9 Chip Resistor - Surface Mount

9 Chip Resistor

9 Capacitors

9 Resistors

8 H AC Board 2 TOP SIDE - 

SURFACE MOUNT

9 Aluminum Capacitor - SM

9 Aluminum Capacitor - SM

Symbol Name

9 Aluminum Capacitor - SM

9 IC

9 IC

9 IC

9 IC - OP Amp

9 MOSFET

9 Chip Resistor - Surface Mount
9 Chip Resistor - Surface Mount

9 Chip Resistor - Surface Mount

9 Schottky Diode Type - SM

9 Capacitors

9 Resistors

Connector - 2 pin

Connetor - 4 pin (blade)

Header - 22 position

B 2 Base plate 

H AC PCB 2 Base plate 

assy-Machining

Symbol Name

H AC PCB 2 Base plate 

assy-Blank

H Cover 

Assembly,
H Screw AC 

Comp Cover

H O-ring, 

Outer, AC 

Compressor

H O-ring, 

Inner, AC 

Compressor

H AC 

Compressor 

Motor Stator 

Asm

H AC Motor 

Stator Stack, 

Machined

tor Stator Plates - w/ 

Holes Materi

tor Stator Plates - 

& No Holes Mate
tor Stator Plates - No 

tor Stator Plates, 3 

no holes - ma

tor Stator Plates - w/3 

 Holes Mate

H AC Motor 

Stator Base

Number

H AC Motor 

Stator Top

H AC Motor 

Stator Insulator 

Liners

H AC Motor 

Stator 

Windings

H AC Motor 
Stator Green 

Terminal with 

3/wires

H AC Motor 

Stator Red 

Terminal with 

3/wires-1

H AC Motor 

Stator Black 

Terminal with 

3/wires-1-1

H AC Motor 

Stator Insulator 

Film

H AC Tie Wrap

H AC Motor 

Stator Winding 

Spacers

H AC Motor 

Stator Wire 

Retainer Cap

H AC Motor 

Stator Retainer 

Material

H Scroll 

Impellar Asm.

Number

H AC Motor 

Magnets and 

Shaft Asm.

tor Shaft, Material
r Weight #1 

H AC Motor Weight 1 

Trimmed

AC Motor Weight #1 Casting

8 AC Motor Weight #1 Material

tor Rotor Endplate 

H AC Motor Rotor Endplate #1 

Material

tor Rotor Plate

Symbol Name

AC Motor Rotor Plate Material

tor Rotor Endplate 

H AC Motor Rotor Endplate #2 

Material
r Weight #2 

H AC Motor Weight 2 

Trimmed

AC Motor Weight #2 Casting

8 AC Motor Weight #2 Material

H Midplate 

Asm.

te, Machined

H Midplate, Trimmed

H Midplate, Diecast

8 H Midplate, Material

Number

H AC Pump, 

Crank Asm.

AC Pump Crank, 
H Shaft, AC Pump Crank, 

Material

AC Pump Crank, 

H Shaft, AC Pump Crank, 

Pin, Machined

H Shaft, AC Pump Crank, Pin, 

Material

ce, AC Pump Crank - 

Symbol Name

H Balance, AC Pump Crank - 

Stamped

H Balance, AC Pump Crank 

Material

H Gasket, AC 

Pump

H Pump 

Transfer 

Guide
H O-ring, 

Outer, AC 

Compressor

H O-ring, 

Inner, AC 

Compressor

H Scroll 

Housing Asm.

H Rear Scroll 

Asm, Scroll 

Housing

croll, Trimmed

H Rear Scroll, Diecast

H Rear Scroll, Aluminum

Number

 Valve, Rear Scroll, 

H Check Valve, Rear Scroll, 

Steel
 Valve Support, 

alve, Stamped

H Check Valve Support, Scroll 

Valve, Steel

tor, Rear Scroll, Oil 

Number

H Spacer, 

Scroll 

Housing, 

Painted
, Scroll Housing, 

H Scroll 

Housing

Housing, Die Cast

H Scroll Housing, Material

H Bolt and 

O-ring Asm., 

Scroll 

Impellar

Number

H Plug, Large, 

Rear Scroll, 

Asm.

H Pressure 

Relief Asm, 

Rear Scroll
H Stud, Rear 

Scroll

To Stud,

H Impeller 

Scroll Asm, 

Scroll 

Housing

er Scroll, Machined

H Impeller Scroll, Trimmed

H Impeller Scroll, Diecast

Symbol Name

8 H Impeller Scroll, Aluminum

H Bolt, Scroll 

Housing, M8 x 

40

H Bolt AC 

Compressor

Qty Material 1 1

1

H Bracket AC 

Compressor 

Casting 

Trimmed

H Bracket AC 

Compressor 

Casting

H Bracket 

Compressor 

Material

2 Commodity 

Pricing

1

1

1

H Housing, 

Compressor 

Motor, 

Washed, Final 

Part
Number Qty

H Housing, 

Compressor 

Motor, 

Machined

H Housing, 

Compressor 

Motor, 

Trimmed

H Housing, 

Compressor 

Motor, 

Casting

H Housing, 

Compressor 

Motor, Alum 

Mtl

H Bearing, 

Needle, 

Compressor 

Motor

H Gasket, 

Terminal 

Passthrough

H Gasket, 

Terminal 

PassthroughStamping

H Terminal 

Block, 

Passthrough 

Asm.

H Plate 

Terminal 

Block, 

Passthrough 

Asm

H Plate 

Terminal 

Block, 

H Leads 

Terminal 

Block, 

Passthrough 

Asm

H Bolt, 

Terminal Block 

Passthrough

H Inductor 
Asm, Coil, 

Large

H Inductor 

Asm, Coil, 

Small

H Capacitor, 

Large

H Terminal 

Block Asm.

H Terminal 

Interface 

Assembly

H AC PCB 1 

preassembled

H AC PCB 1 w 

all 

components

H AC PCB 1 w 

Thru Hole 

mntd

H AC PCB 1 w 

SMT mntd

H AC Board 1 

Bare FR4

H AC board 1 

BOTTOM 

SIDE

64F7047FRK4

0

TY2464A

4274DV5

Number

M6IT 803 00

M6IT 803 00

M43T 749 01

H1050Q 07CT 

A4L1G4

E85
9001FNG 

810A4

51

L273

IC Unmarked

MOSFET

100

101

221

221

10000

KSS807F

S93A66 

ADAVH4 1439

T7D

Schottky Diode

Capacitors

Resistors

Number

H AC board 1 

TOP SIDE - 

SURFACE 

MOUNT

PCE3155TRND

PCE3146TRND

PCE3156TRND

ST70-27MF
"2SC3303-O

(T6L1,NQ)-ND"

BZX84C27-

FDITR-ND

"TE85L,Q,M"

NCV4274ADT

33RKGOSTRND

MMSZ4679T1

GOSTR-ND

BAT 63-02V 

E6327-ND-1

257-1149-1-

ND

641-1255-2-

ND

Capacitors

Resistors

12124898

SAM1111-22-

ND

H Bracket AC 

PCB 

1connector

Number Qty

H Bracket AC 

PCB 

1connectorBlank

H Screw IGBT 

to base

H AC PCB 2 

preassembled

H AC PCB 2 

wo metal base

H AC PCB 2 w 

all 
components

H AC PCB 2 w 

thru hole 

mnted

H AC PCB 2 w 

SMT mnted

H AC Board 2 

Bare FR4

H AC Board 2 

BOTTOM 

SIDE - 

SURFACE 

MOUNT

RHM.

002AUTR-ND

541-1.

0XTR-ND

Capacitors

Resistors

H AC Board 2 

TOP SIDE - 

SURFACE 

MOUNT

PCE3155TRND

PCE3155TRND

Number

PCE3155TRND

IR2113SPBFC

T-ND-1

IR2113SPBFC

T-ND-1

IR2113SPBFC

T-ND-1

TLV2464AIPW

BSS84CT-ND

HVCB1206T21
00MFICT-ND

HMC1/8200MK

R-ND

CRCW201030

0RFKTF-ND

MA2Q70500L

CT-ND

Capacitors

Resistors

H AC Board 2 

Connector - 2 

pin

H AC Board 2 

Connetor - 4 

pin (blade)

SAM1111-22-

ND

H AC PCB 2 

Base plate 

assy

H AC PCB 2 

Base plate 

assy-Washing

H AC PCB 2 

Base plate 

assy-

Machining

Number

H AC PCB 2 

Base plate 

assy-Blank

IRGP30B60KD

-EP-ND

H Screw IGBT 

to base

H screw AC 

PCB 2 wire 

lead

H Screw IGBT 

to base

1
H Cover 

Compressor 

Housing

H Cover 

Compressor 

Housing-Blank

H Sticker, 

Warning, 

Compressor

H Sticker, 

Informational, 

Compressor

11

111

1

H AC Motor 

Stator Stack

Number Qty

H AC Motor 

Stator Plates - 

w/Alignment 

Notch & Hol

H AC Motor 

Stator Plates - 

w/Notch & 

Holes Matl

H AC Motor 

Stator Plates - 

w/Alignment 

Notch

H AC Motor 

Stator Plates - 
w/Notch & No 

Holes Mate

H AC Motor 

Stator Plates - 

No Notch

H AC Motor 

Stator Plates - 

No Notch 

Material

H AC Motor 

Stator Plates - 

3 notches - no 

holes

H AC Motor 

Stator Plates, 3 

notches, no 

holes - ma

H AC Motor 

Stator Plates - 

3 notches 

plus holes

H AC Motor 

Stator Plates - 

w/3 Notche & 

Holes Matl

1

Qty

H AC Motor 

Stator Base 

Material

1

H AC Motor 

Stator Top 

Material

991
11129

1

1

1

Qty

1

H AC Motor 

Shaft

H AC Motor 

Shaft, 

Machined

H AC Motor 

Shaft, Material

H AC Motor 

Rotor Asm, 

Riveted

H AC Motor 

Rivets

H AC Motor 
Weight #1

AC Motor 

Weight #1 

Deburred

H AC Motor 

Weight 1 

Trimmed

AC Motor 

Weight #1 

Casting

AC Motor 

Weight #1 

Material

H AC Motor 

Rotor 

Endplate #1

H AC Motor 

Rotor 

Endplate #1 

Stamped

H AC Motor 

Rotor Endplate 

#1 Material

H Ac Motor 

Rotor Asm

H AC Motor 

Rotor Plate

Number

AC Motor 

Rotor Plate 

Material

H AC Motor 

Magnets

H AC Motor 

Rotor 

Endplate #2

H AC Motor 

Rotor 

Endplate #2 

Stamped

H AC Motor 

Rotor Endplate 

#2 Material

H AC Motor 

Weight #2
H AC Motor 

Weight #2 

Deburred

H AC Motor 

Weight 2 

Trimmed

H AC Motor 

Weight #2 

Casting

H AC Motor 

Weight #2 

Material

1

H Midplate

H Midplate, 

Deburred

H Midplate, 

Machined

H Midplate, 

Trimmed

H Midplate, 

Diecast

H Midplate, 

Material

Qty

H Bearing, AC 

Pump

H Dowel Pin, 

Midplate Asm.

H Dowel Pin, 

Small, Midplate 

Asm

1

H Shaft, AC 

Pump Crank, 

Asm

H Shaft, AC 

Pump Crank, 

Washed

H Shaft, AC 

Pump Crank, 

Machined
H Shaft, AC 

Pump Crank, 

Material

H Shaft, AC 

Pump Crank, 

Pin

H Shaft, AC 

Pump Crank, 

Pin, Deburred

H Shaft, AC 

Pump Crank, 

Pin, Machined

H Shaft, AC 

Pump Crank, 

Pin, Material

H Balance, AC 

Pump Crank, 

Washed

H Balance, AC 

Pump Crank

H Balance, AC 

Pump 

CrankMachined

Number

H Balance, AC 

Pump 

CrankMachinedStamped

H Balance, AC 

Pump Crank 

Material

H Rubber 

Bushing, On 

Post

1

H Gasket, AC 

Pump Material

1
H Pump 

Transfer Guide 

Material

111

1

H Rear Scroll

H Rear Scroll, 

Machined

H Rear Scroll, 

Trimmed

H Rear Scroll, 

Diecast

H Rear Scroll, 

Aluminum

Qty

H Check 

Valve, Rear 

Scroll

H Check 

Valve, Rear 

Scroll, 

Deburred

H Check 

Valve, Rear 

Scroll, 

Stamped

H Check 

Valve, Rear 

Scroll, Steel

H Check 

Valve 

Support, 

Scroll Valve

H Check 
Valve 

Support, 

Scroll Valve, 

Deburred

H Check 

Valve 

Support, 

Scroll Valve, 

Stamped

H Check Valve 

Support, Scroll 

Valve, Steel

H Bolt, Scroll 

Valve, M6 x 12

H Restrictor, 

Rear Scroll, 

Oil Passage

H Restrictor, 

Rear Scroll, 

Oil Passage, 

Machined

H Restrictor, 

Rear Scroll, Oil 

Passage, Steel

Qty

H Filter 

Screen, Rear 

Scroll, Oil 

Passage

H O-ring, Rear 

Scroll

H Seal, Spiral, 

Scroll

H Seal, Spiral, 

Vespel

1

H Spacer, 

Scroll 

Housing, 

Washed

H Spacer, 

Scroll 
Housing, 

Stamped

H Spacer, 

Scroll Housing, 

MPM Material

1

H Scroll 

Housing, 

Machined

H Scroll 

Housing, 

Trimmed

H Scroll 

Housing, Die 

Cast

H Scroll 

Housing, 

Material

3

Qty

H Bolt, Scroll 

Housing, 

Impellar

H O-ring, Bolt, 

Scroll Impellar

1

H Plug, Large, 

Rear Scroll

H O-ring, 

Large Plug

1

H Pressure 

Relief, Rear 

Scroll

H O-ring, Rear 

Scroll, 

Pressure Relief
1

1

1

H Impeller 

Scroll

H Impeller 

Scroll, 

Anodize

H Impeller 

Scroll, 

Machined

H Impeller 

Scroll, 

Trimmed

H Impeller 

Scroll, 

Diecast

Number

H Impeller 

Scroll, 

Aluminum

H Bearing, 

Needle, 

Impeller 

Scroll

H Seal, Spiral, 

Scroll

H Seal, Spiral, 

Vespel

4

3 Commodity 

Pricing

Piece Cost

Aluminum - 

380

Aluminum - 

380

1 Aluminum - 

380

1 Aluminum - 

380

1 Aluminum - 

380

1

Page 1 of
Material

1 Aluminum 

A380

1 Aluminum 

A380

1 Aluminum 

A380

1 Aluminum 

A380

1 Commodity 

Pricing

1

1 PMP Plastic 

Metal Plastic

1

1

1 Steel - 1008

3 Commodity 

Prcing

2 Commodity 

Prcing

1 Commodity 
Prcing

1 Commodity 

Prcing

1 Commodity 

Prcing

1 Commodity 

Prcing

1 Commodity 

Prcing

1

1

1

1

1 Commodity 

Pricing

1

1 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

Page 3 of

Qty Material 1 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 
Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

2 Commodity 

Pricing

2 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

47 Commodity 

Pricing

61 Commodity 

Pricing

Page 4 of

Qty Material 1

8 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 
Pricing

1 Commodity 

Pricing

2 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

2 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

57 Commodity 

Pricing

28 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

1

Page 5 of

Material

1 Galvinized 

Steel - G60

4 Commodity 

Prcing

1

1

1
1

1

1 Commodity 

Pricing

1

63

19

19

1

11

Page 6 of

Qty

1

111113
4

2

3

14

36

1 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

1

1 Aluminum - 

30xx

1

Page 7 of

Qty Material

1 Aluminum - 

30xx

6 Commodity 

Pricing

6 Commodity 

Prcing

1 Commodity 

Prcing

4 Commodity 

Prcing
1

1

PMP Plastic 

Metal Plastic

1 Commodity 

Pricing

1 Commodity 

Pricing

Commodity 

Pricing

Commodity 

Pricing

Commodity 

Pricing

Steel - 1018

1 Steel 1018

Page 8 of

Material

13

1 Steel - 1018

17 Steel - EM

1 Steel - 1018
144 Steel - EM

1 Steel 1018

14 Steel - EM

1 Steel - 1018

15 Steel - EM

1 Steel 1018

Nylon 6/6 (GF)

Page 9 of

Material

1 PA66 GF30

Nylon 6/6 (GF)

1 PA66

Nylon 6/6

Commodity 

Pricing

Commodity 
Pricing

Commodity 

Pricing

Commodity 

Pricing

Nylon 6/6

Commodity 

Pricing

Nylon 6/6

Nylon 6/6 (GF)

PA66 GF30

Page 10 of

Material Piece Cost

1 Steel - 1040

1 Steel - 1040

1 Steel - 1040

1

4 Commodity 

Pricing

1 Brass
1 Brass

1

1

1 Brass

1

1

1 Steel - 1008

1

178 Steel - 1008

Page 11 of

Qty Material

1 Steel - 1008

6 Molded 

Magnet

1

1

1 Steel - 1008

1 Brass
1 Brass

1

1 Brass

1 Brass

1

1

1

1

1

1 Aluminum

Page 12 of

Material

1 Commodity 

Pricing

2 Commodity 

Pricing

2 Commodity 

Pricing

1

1

1
1 Steel - 1018

1 Steel - 1018

1

1

1 Steel - 1040

1

1

1

Page 13 of

Qty Material

1

1 Steel - 1008

1 Commodity 

Pricing

1 Steel Roll 

Formed

Aluminum - 

380
1 Aluminum - 

380

Commodity 

Pricing

Commodity 

Pricing

1 Aluminum

1 Aluminum

1 Aluminum

1 Aluminum

1 Aluminum

Page 14 of

Material

1 Steel - 1040

1 Steel - 1040

1 Steel - 1040

1 Steel - 1040

1 Steel - 1018

1 Steel - 1018
1 Steel - 1018

1 Steel - 1018

1 Commodity 

Pricing

1 Steel - 1008

1 Steel - 1008

1 Steel - 1008

Page 15 of

Material

1 Commodity 

Pricing

1 Commodity 

Pricing

1 Vespel 

Carbon Filled

1 Vespel Carbon 

Filled

MPM (Metal 

Plastic Metal)

1 MPM (Metal 

Plastic Metal)

1 MPM (Metal 

Plastic Metal)
1 MPM (Metal 

Plastic Metal)

Aluminum

1 Aluminum

1 Aluminum

1 Aluminum

1 Aluminum

Page 16 of

Material

1 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing

1 Commodity 

Pricing
Commodity 

Pricing

Commodity 

Pricing

1 Aluminum

1 Aluminum

1 Aluminum

1 Aluminum

1 Aluminum

Page 17 of

Qty Material

1 Aluminum

1

1 Vespel 

Carbon Filled

1 Vespel Carbon 

Filled

Commodity 

Pricing
Page 18 of
Weight

$0.51

$0.51

$0.51

$0.51

$0.51

$0.51

$0.13

$130.59

$100.67

$100.06

$5.06

18
Piece Cost

$5.06

$5.06

$0.30

$0.01

$0.01

$0.54

$0.09

$0.09

$0.15

$0.03

$1.50
$1.00

$1.25

$0.40

$0.55

$40.56

$40.56

$40.56

18

Piece Cost
18

Piece Cost
$0.07

18

Piece Cost

$0.07

$0.02

$48.61

$24.97

$24.97
Commodity 

Pricing

Commodity 

Pricing

Commodity 

Pricing

Commodity 

Pricing

Commodity 

Pricing

Commodity 

Pricing

18

Material Piece Cost

Commodity 

Pricing

Commodity 

Pricing

Commodity 

Pricing

Commodity 

Pricing

Commodity 

Pricing

Commodity 

Pricing

Commodity 
Pricing

Commodity 

Pricing

Commodity 

Pricing

Commodity 

Pricing

Commodity 

Pricing

Commodity 

Pricing

$0.29

$0.29

18

Piece Cost

$3.87

$0.02

$0.01

$0.02

$0.38
$0.28

$0.28

$0.05

$0.05

$0.02

$0.05

$0.05

$11.36

$3.86

$3.86

18

Piece Cost

$0.02

$0.02

$0.02

$0.02
$0.02

$0.02

$0.02

$0.02

$0.02

$0.02

$0.07

18

Piece Cost Weight

$0.07

$0.08

$0.08

$0.02

$0.73

$0.16
$0.16

$0.16

$0.01

$0.01

$0.01

$0.08

$0.08

$11.97

18

Weight

$7.17

$1.14

$1.14

$1.14

$6.03

$0.09

$0.19
$0.19

$0.02

$0.02

$1.42

$0.01

18

Piece Cost

$0.65

$0.02

$0.02

$0.12
$0.12

$3.35

$0.86

$0.86

$0.86

18

Piece Cost Weight

$2.43

$0.02

$0.01

$0.42

$0.12

$0.11

$0.11
$0.01

$0.01

$0.27

$0.27

$0.27

18

Piece Cost

$0.03

$0.62

$0.62

$0.41
$0.41

$0.05

$0.05

$6.06

$1.25

$0.85

$0.85

$0.85

18

Piece Cost Weight

$0.01

$0.01

$0.01

$0.04

$0.04
$0.04

$0.02

$0.01

$0.01

$0.01

18

Piece Cost Weight

$0.10

$0.06

$0.18

$0.18

$0.09

$0.09

$0.09
$0.09

$2.37

$2.37

$2.37

$2.37

$0.09

18

Piece Cost Weight

$0.05

$0.03

$0.21

$0.18

$0.04

$0.29

$0.25

$0.04
$0.04

$0.04

$1.50

$0.68

$0.68

$0.68

18

Piece Cost

$0.64

$0.18

$0.18

$0.07

$0.18
18
Piece Cost 

(Total)

0.4270 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0780 lb

16.6728 lb

5.5046 lb

5.1979 lb

4.3755 lb
Weight Piece Cost 

(Total)

4.3755 lb

4.3755 lb

$5.06

$5.06

0.0046 lb

0.0040 lb

0.0040 lb

0.1214 lb

0.0914 lb

0.0914 lb

0.0100 lb

0.0137 lb

0.2579 lb
0.1460 lb

0.2271 lb

0.0340 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

$36.46

$3.41

$24.66

$12.30

$0.40

$1.29

Weight

$0.92

$0.92

$0.92

$0.84

$0.15
$2.33

$0.07

$0.07

$0.09

$0.06

$0.02

$0.02

$0.70

$0.70

$0.33

$1.18

$0.05

$0.07

$0.01

$0.01

Weight

$8.40

$0.32

$0.32

$0.37

$0.02
$0.47

$0.02

$0.15

$1.30

$0.02

$0.11

$1.92

$0.18

$0.01

$0.01

$2.25

$1.85

0.0000 lb

Weight Piece Cost 

(Total)

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb
$24.97

$22.77

$2.64

$2.20

$0.29

$0.03

$0.01

$0.01

$17.93

$0.32

$0.32

Weight

$0.32

$1.15

$1.15

$1.15

$1.48

$0.06

$2.80
$0.51

$0.09

$0.29

$0.01

$0.01

$0.15

$0.20

$1.85

0.0000 lb

0.0000 lb

$0.29

Weight

$0.29

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.3050 lb
0.3042 lb

0.3042 lb

0.0004 lb

0.0004 lb

0.0000 lb

0.0031 lb

0.0029 lb

3.1601 lb

2.8500 lb

2.8500 lb

Weight Piece Cost 

(Total)

0.0000 lb

0.0000 lb

0.0150 lb

0.0000 lb
0.0150 lb

0.0000 lb

0.0150 lb

0.0000 lb

0.0150 lb

0.0000 lb

0.0330 lb

Piece Cost 

(Total)

0.0000 lb

0.0400 lb

0.0000 lb

0.0230 lb

0.0000 lb

0.0099 lb
0.0000 lb

0.0066 lb

0.0010 lb

0.0000 lb

0.0014 lb

0.0370 lb

0.0000 lb

3.9635 lb

Piece Cost 

(Total)

2.6527 lb

0.7620 lb

0.0000 lb

0.0000 lb

1.8907 lb

0.0200 lb

0.1100 lb
0.0000 lb

$0.19

$0.19

$0.19

0.0205 lb

0.0205 lb

$0.02

1.3172 lb

0.0074 lb

Weight

$0.01

0.0452 lb

0.0189 lb

0.0189 lb

$0.02

0.0700 lb
0.0000 lb

$0.12

$0.12

$0.12

1.0394 lb

0.7463 lb

0.0000 lb

0.0000 lb

$0.86

$0.86

$0.86

Piece Cost 

(Total)

0.2771 lb

0.0080 lb

0.0000 lb

0.1306 lb

0.1302 lb

0.1263 lb

0.0000 lb
$0.11

0.0039 lb

0.0000 lb

$0.01

$0.01

0.0000 lb

0.0000 lb

0.0000 lb

Weight

$0.27

$0.27

0.0003 lb

0.0252 lb

0.0000 lb

0.1156 lb
0.0000 lb

0.0031 lb

0.0029 lb

3.8068 lb

0.7929 lb

0.7316 lb

0.7316 lb

0.7316 lb

$0.85

$0.85

Piece Cost 

(Total)

0.0042 lb

0.0042 lb

0.0042 lb

$0.01

0.0335 lb

0.0335 lb
0.0335 lb

$0.04

0.0108 lb

0.0062 lb

0.0062 lb

0.0062 lb

Piece Cost 

(Total)

0.0013 lb

0.0025 lb

0.0028 lb

0.0028 lb

0.0312 lb

0.0312 lb

0.0312 lb
0.0312 lb

2.0550 lb

2.0550 lb

2.0550 lb

2.0550 lb

$2.37

0.0382 lb

Piece Cost 

(Total)

0.0380 lb

0.0002 lb

0.1259 lb

0.1256 lb

0.0003 lb

0.0111 lb

0.0108 lb

0.0003 lb
0.0294 lb

0.0155 lb

0.6312 lb

0.5874 lb

0.5874 lb

0.5874 lb

$0.68

$0.68

Weight

$0.68

0.0410 lb

0.0028 lb

0.0028 lb

0.0472 lb

0.0930 lb

Weight (Total)

$0.51 0.4270 lb

$0.51

$0.51

$0.51

$0.51

$0.51

$0.26 0.1560 lb

$130.59 16.6728 lb

$100.67

$100.06

$5.06
Weight (Total)

$5.06

$5.06

4.3755 lb $5.06

4.3755 lb $5.06

$0.30

$0.01

$0.01

$0.54

$0.09

$0.09

$0.45

$0.06

$1.50
$1.00

$1.25

$0.40

$0.55

$40.56

$40.56

$40.56

0.0000 lb $36.46

0.0000 lb $3.41

0.0000 lb $24.66

0.0000 lb

0.0000 lb

0.0000 lb

Piece Cost 

(Total)

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb
0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

Piece Cost 

(Total)

0.0000 lb $8.40

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb
0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb $2.25

0.0000 lb $1.85

$0.07

Weight (Total)

$0.07

$0.08

$48.61

$24.97

$24.97
0.0000 lb $24.97

0.0000 lb $22.77

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

Piece Cost 

(Total)

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb
0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb $0.15

0.0000 lb $0.20

0.0000 lb $1.85

$0.29

$0.29

0.0000 lb $0.29

Piece Cost 

(Total)

0.0000 lb $0.29

$23.22

$0.12

$0.01

$0.08

$0.38
$0.28

$0.28

$0.05

$0.05

$0.22

$0.05

$0.05

$11.36

$3.86

$3.86

Weight (Total)

$0.25

$0.25

$0.32

$0.32
$2.74

$2.74

$0.27

$0.27

$0.29

$0.29

$0.07

Weight (Total)

$0.07

$0.08

$0.08

$0.18

$6.57

$0.16
$0.16

$0.16

$0.01

$0.02

$0.09

$0.08

$0.08

$11.97

Weight (Total)

$7.17

$1.14

$1.14

$1.14

$6.03

$0.36

$0.19
$0.19

0.0000 lb $0.19

0.0000 lb $0.19

0.0000 lb

$0.02

$0.02

0.0000 lb $0.02

$1.42

$1.42

Piece Cost 

(Total)

0.0000 lb $1.42

$3.90

$0.02

$0.02

0.0000 lb $0.02

$0.12
$0.12

0.0000 lb $0.12

0.0000 lb $0.12

0.0000 lb

$3.35

$0.86

$0.86

$0.86

0.0000 lb $0.86

0.0000 lb $0.86

0.0000 lb

Weight (Total)

$2.43

$0.04

$0.02

$0.42

$0.12

$0.11

$0.11
0.0000 lb $0.11

$0.01

$0.01

0.0000 lb $0.01

0.0000 lb $0.01

$0.27

$0.27

$0.27

Piece Cost 

(Total)

0.0000 lb $0.27

0.0000 lb $0.27

$0.03

$0.62

$0.62

$0.41
$0.41

$0.05

$0.05

$6.06

$1.25

$0.85

$0.85

$0.85

0.7316 lb $0.85

0.7316 lb $0.85

Weight (Total)

$0.01

$0.01

$0.01

0.0042 lb $0.01

$0.04

$0.04
$0.04

0.0335 lb $0.04

$0.02

$0.01

$0.01

$0.01

Weight (Total)

$0.10

$0.06

$0.18

$0.18

$0.09

$0.09

$0.09
$0.09

$2.37

$2.37

$2.37

$2.37

2.0550 lb $2.37

$0.26

Weight (Total)

$0.16

$0.09

$0.21

$0.18

$0.04

$0.29

$0.25

$0.04
$0.04

$0.04

$1.50

$0.68

$0.68

$0.68

0.5874 lb $0.68

0.5874 lb $0.68

Piece Cost 

(Total)

0.5874 lb

$0.64

$0.18

$0.18

$0.27

$0.53 0.2790 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

5.5046 lb

5.1979 lb

4.3755 lb
4.3755 lb

4.3755 lb

4.3755 lb

4.3755 lb

0.0046 lb

0.0040 lb

0.0040 lb

0.1214 lb

0.0914 lb

0.0914 lb

0.0300 lb

0.0274 lb

0.2579 lb
0.1460 lb

0.2271 lb

0.0340 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

$12.30 0.0000 lb

$0.40 0.0000 lb

$1.29 0.0000 lb

Weight (Total)

$0.92 0.0000 lb

$0.92 0.0000 lb

$0.92 0.0000 lb

$0.84 0.0000 lb

$0.15 0.0000 lb
$2.33 0.0000 lb

$0.07 0.0000 lb

$0.07 0.0000 lb

$0.19 0.0000 lb

$0.12 0.0000 lb

$0.02 0.0000 lb

$0.02 0.0000 lb

$0.70 0.0000 lb

$0.70 0.0000 lb

$0.33 0.0000 lb

$1.18 0.0000 lb

$0.05 0.0000 lb

$0.07 0.0000 lb

$0.47 0.0000 lb

$0.61 0.0000 lb

Weight (Total)

0.0000 lb

$2.54 0.0000 lb

$0.32 0.0000 lb

$0.37 0.0000 lb

$0.02 0.0000 lb
$0.47 0.0000 lb

$0.04 0.0000 lb

$0.15 0.0000 lb

$1.30 0.0000 lb

$0.02 0.0000 lb

$0.22 0.0000 lb

$1.92 0.0000 lb

$0.18 0.0000 lb

$0.57 0.0000 lb

$0.28 0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb
0.0000 lb

0.0000 lb

$2.64 0.0000 lb

$2.20 0.0000 lb

$1.72 0.0000 lb

$0.10 0.0000 lb

$0.19 0.0000 lb

$0.19 0.0000 lb

$17.93 0.0000 lb

$0.32 0.0000 lb

$0.32 0.0000 lb

Weight (Total)

$0.32 0.0000 lb

$1.15 0.0000 lb

$1.15 0.0000 lb

$1.15 0.0000 lb

$1.48 0.0000 lb

$0.06 0.0000 lb

$8.40 0.0000 lb
$2.04 0.0000 lb

$0.18 0.0000 lb

$0.87 0.0000 lb

$0.14 0.0000 lb

$0.36 0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

Weight (Total)

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.3050 lb
0.3042 lb

0.3042 lb

0.0004 lb

0.0004 lb

0.0000 lb

0.0031 lb

0.0029 lb

3.1601 lb

2.8500 lb

2.8500 lb

0.0000 lb

0.0000 lb

0.2550 lb

0.0000 lb
2.1600 lb

0.0000 lb

0.2100 lb

0.0000 lb

0.2250 lb

0.0000 lb

0.0330 lb

0.0000 lb

0.0400 lb

0.0000 lb

0.2070 lb

0.0000 lb

0.0099 lb
0.0000 lb

0.0066 lb

0.0010 lb

0.0000 lb

0.0126 lb

0.0370 lb

0.0000 lb

3.9635 lb

2.6527 lb

0.7620 lb

0.0000 lb

0.0000 lb

1.8907 lb

0.0800 lb

0.1100 lb
0.0000 lb

0.0000 lb

0.0000 lb

$0.19 0.0000 lb

0.0205 lb

0.0205 lb

0.0000 lb

1.3172 lb

1.3172 lb

Weight (Total)

0.0000 lb

0.2712 lb

0.0189 lb

0.0189 lb

0.0000 lb

0.0700 lb
0.0000 lb

0.0000 lb

0.0000 lb

$0.12 0.0000 lb

1.0394 lb

0.7463 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

$0.86 0.0000 lb

0.2771 lb

0.0160 lb

0.0000 lb

0.1306 lb

0.1302 lb

0.1263 lb

0.0000 lb
0.0000 lb

0.0039 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

Weight (Total)

0.0000 lb

0.0000 lb

0.0003 lb

0.0252 lb

0.0000 lb

0.1156 lb
0.0000 lb

0.0031 lb

0.0029 lb

3.8068 lb

0.7929 lb

0.7316 lb

0.7316 lb

0.7316 lb

0.7316 lb

0.7316 lb

0.0042 lb

0.0042 lb

0.0042 lb

0.0042 lb

0.0335 lb

0.0335 lb
0.0335 lb

0.0335 lb

0.0108 lb

0.0062 lb

0.0062 lb

0.0062 lb

0.0013 lb

0.0025 lb

0.0028 lb

0.0028 lb

0.0312 lb

0.0312 lb

0.0312 lb
0.0312 lb

2.0550 lb

2.0550 lb

2.0550 lb

2.0550 lb

2.0550 lb

0.1146 lb

0.1140 lb

0.0006 lb

0.1259 lb

0.1256 lb

0.0003 lb

0.0111 lb

0.0108 lb

0.0003 lb
0.0294 lb

0.0155 lb

0.6312 lb

0.5874 lb

0.5874 lb

0.5874 lb

0.5874 lb

0.5874 lb

Weight (Total)

$0.68 0.5874 lb

0.0410 lb

0.0028 lb

0.0028 lb

0.1888 lb

Indented Bill of Materials

H AC Systems

Level Symbol Name Number Qty

H Bracket AC Compressor H Bracket AC 1

Mount to Block Compressor 

Mount to 

Block

0 H Bolt AC Compressor Bracket H Bolt AC 2

Compressor 

Bracket

0 H Electric AC Compressor H Electric AC 1

Assembly Compressor 

Assembly

1 H Housing, Coil, and H Housing, 1

Electronics Asm. Coil, and 

Electronics 

Asm.

2 H Housing Asm., Potted H Housing 

Electronics Asm., Potted 

Electronics

3 H Housing, Compressor H Housing, 

Motor, Washed, Final Part Compressor 

Motor, 

Washed, Final 

Part

4 H Housing, Compressor H Housing, 

Motor, Machined Compressor 

Motor, 

Machined

5 H Housing, Compressor H Housing, 

Motor, Trimmed Compressor 

Motor, 

Trimmed

6 H Housing, Compressor H Housing, 

Motor, Casting Compressor 

Motor, 

Casting

7 H Housing, Compressor Motor, H Housing, 

Alum Mtl Compressor 

Motor, Alum 

Mtl

Design Profit®
Copyright 2005© Munro & Associates, Inc.
H AC Systems

Level Symbol Name Number

3 H Bearing, Needle, H Bearing, 

Compressor Motor Needle, 

Compressor 

Motor

3 H Gasket, Terminal H Gasket, 

Passthrough Terminal 

Passthrough

4 H Gasket, Terminal H Gasket, 

Passthrough Terminal 

PassthroughStamping

3 H Terminal Block, H Terminal 

Passthrough Asm. Block, 

Passthrough 

Asm.

4 H Plate Terminal Block, H Plate 

Passthrough Asm Terminal 

Block, 

Passthrough 

Asm

5 H Plate Terminal Block, H Plate 

Passthrough Asm Terminal 

Block, 

Passthrough 

Asm-blank

4 H Leads Terminal Block, H Leads 

Passthrough Asm Terminal 

Block, 

Passthrough 

Asm

3 H Bolt, Terminal Block H Bolt, 

Passthrough Terminal Block 

Passthrough

3 H Inductor Asm, Coil, Large H Inductor 

Asm, Coil, 

Large

3 H Inductor Asm, Coil, Small H Inductor 

Asm, Coil, 

Small

3 H Capacitor, Large H Capacitor, 

Large

3 H Terminal Block Asm. H Terminal 

Block Asm.

3 H Terminal Interface H Terminal 

Assembly Interface 

Assembly

3 H AC PCB 1 preassembled H AC PCB 1 

preassembled

4 H AC PCB 1 w all H AC PCB 1 w 

components all 

components

5 H AC PCB 1 w Thru Hole H AC PCB 1 w 

mntd Thru Hole 

mntd

6 H AC PCB 1 w SMT mntd 1 H AC Board 1 Bare FR4 FR4 2 H AC board 1 BOTTOM SIDE 3 IC H8 MCU FLASH 256K 100TQFP 64F7047FRK40 4 IC - OP Amp TY2464A 5 IC - Voltage Regulator 4274DV5 6 IC - OPTOCOUPLER M6IT 803 00 7 IC - OPTOCOUPLER M6IT 803 00 8 IC - Optoisolators M43T 749 01 9 IC - Transceiver H1050Q 07CT A4L1G4

10 Diode E85

11 IC - Digital to Analog Converter 9001FNG 810A4

12 Zener Diode 51

13 IC - Bridge Rectifier L273

14 IC Unmarked IC Unmarked

15 MOSFET MOSFET

16 Chip Resistor - Surface Mount 100

17 Chip Resistor - Surface Mount 101

18 Inductor 221

19 Inductor 221

20 10000 KSS807F 10000 KSS807F

21 MOSFET S93A66 ADAVH4 1439

22 Diode T7D

23 Schottky Diode Schottky Diode

24 Capacitors Capacitors

25 Resistors Resistors

26 H AC board 1 TOP SIDE - SURFACE MOUNT

27 Aluminum Capacitor - SM PCE3155TR-ND

28 Aluminum Capacitor - SM PCE3146TR-ND

29 Aluminum Capacitor - SM PCE3156TR-ND

30 Zener Diode - SM ST70-27MF
31 Transistors (BJT) - SM "2SC3303-O(T6L1,NQ)-ND"

32 Zener Diode - SM BZX84C27-FDITR-ND

33 Diode "TE85L,Q,M"

34 IC REG LDO 400MA 5.0V DPAK NCV4274ADT33RKGOSTR-ND

35 Zener Diode MMSZ4679T1GOSTR-ND

36 Schottky Diode BAT 63-02V E6327-ND-1

37 Transformer - SM 257-1149-1-ND

38 Schottky Diode 641-1255-2-ND

39 Capacitors Capacitors

40 Resistors Resistors

41 Connector Asm - 8 position 12124898

42 Header - 22 position SAM1111-22-ND

3 H Bracket AC PCB H Bracket AC 

1connector PCB 

1connector

4 H Bracket AC PCB H Bracket AC 

1connector-Blank PCB 

1connectorBlank

3 H Screw IGBT to base H Screw IGBT 

to base

3 H AC PCB 2 preassembled H AC PCB 2 

preassembled

4 H AC PCB 2 wo metal base H AC PCB 2 

wo metal base

5 H AC PCB 2 w all H AC PCB 2 w 

components all 

components

6 H AC PCB 2 w thru hole H AC PCB 2 w 

mnted thru hole 

mnted

7 H AC PCB 2 w SMT mnted H AC PCB 2 w 

SMT mnted

8 H AC Board 2 Bare FR4

Bottom

9 Chip Resistor - Surface Mount

9 Chip Resistor

9 Capacitors

9 Resistors

Top

9 Aluminum Capacitor - SM

9 Aluminum Capacitor - SM

9 Aluminum Capacitor - SM

9 IC
9 IC

9 IC

9 IC - OP Amp

9 MOSFET

9 Chip Resistor - Surface Mount

9 Chip Resistor - Surface Mount

9 Chip Resistor - Surface Mount

9 Schottky Diode Type - SM

9 Capacitors

9 Resistors

Thru Hole

7 Connector - 2 pin

7 Connetor - 4 pin (blade)

7 Header - 22 position

4 H AC PCB 2 Base plate assy H AC PCB 2 

Base plate 

assy

5 H AC PCB 2 Base plate H AC PCB 2 

assy-Washing Base plate 

assy-Washing

6 H AC PCB 2 Base plate H AC PCB 2 

assy-Machining Base plate 

assyMachining

7 H AC PCB 2 Base plate H AC PCB 2 

assy-Blank Base plate 

assy-Blank

4 IC IGBT - Screw Attachment IRGP30B60KD

-EP-ND

4 H Screw IGBT to base H Screw IGBT 

to base

4 H screw AC PCB 2 wire lead H screw AC 

PCB 2 wire 

lead

3 H Screw IGBT to base H Screw IGBT 

to base

2 H Cover Assembly H Cover 

Assembly,

3 H Cover Compressor H Cover 

Housing Compressor 

Housing

4 H Cover Compressor Housing H Cover 

Compressor 

Housing-Blank

Design Profit®
Copyright 2005© Munro & Associates, Inc.
H AC Systems

Level Symbol Name Number

3 H Sticker, Warning, H Sticker, 

Compressor Warning, 

Compressor

3 H Sticker, Informational, H Sticker, 

Compressor Informational, 

Compressor

2 H Screw IGBT to base H Screw AC 

Comp Cover

1 H O-ring, Outer, AC H O-ring, 1

Compressor Outer, AC 

Compressor

1 H O-ring, Inner, AC H O-ring, 1

Compressor Inner, AC 

Compressor

1 H Scroll Impeller Asm. H Scroll 1

Impellar Asm.

2 H AC Motor Magnets and H AC Motor 

Shaft Asm. Magnets and 

Shaft Asm.

3 H AC Motor Shaft H AC Motor 

Shaft

3 H AC Motor Magnets H AC Motor 

Magnets

3 H Ac Motor Rotor Asm H Ac Motor 

Rotor Asm

4 H AC Motor Rotor Plate H AC Motor 

Rotor Plate

2 H Midplate Asm. H Midplate 

Asm.

3 H Midplate, Washed H Midplate

4 H Midplate, Deburred H Midplate, 

Deburred

5 H Midplate, Machined H Midplate, 

Machined

6 H Midplate, Trimmed H Midplate, 

Trimmed

7 H Midplate, Diecast H Midplate, 

Diecast

8 H Midplate, Material H Midplate, 

Material

3 H Bearing, AC Pump H Bearing, AC 

Pump

Design Profit®
Copyright 2005© Munro & Associates, Inc.
H AC Systems

Level Symbol Name Number

3 H Dowel Pin, Midplate Asm. H Dowel Pin, 

Midplate Asm.

3 H Dowel Pin, Small, Midplate H Dowel Pin, 

Asm Small, Midplate 

Asm

2 H AC Pump, Crank Asm. H AC Pump, 

Crank Asm.

3 H Shaft, AC Pump Crank, H Shaft, AC 

Asm Pump Crank, 

Asm

4 H Shaft, AC Pump Crank, H Shaft, AC 

Washed Pump Crank, 

Washed

5 H Shaft, AC Pump Crank, H Shaft, AC 

Machined Pump Crank, 

Machined

6 H Shaft, AC Pump Crank, H Shaft, AC 

Material Pump Crank, 

Material

4 H Shaft, AC Pump Crank, Pin H Shaft, AC 

Pump Crank, 

Pin

5 H Shaft, AC Pump Crank, H Shaft, AC 

Pin, Deburred Pump Crank, 

Pin, Deburred

6 H Shaft, AC Pump Crank, H Shaft, AC 

Pin, Machined Pump Crank, 

Pin, Machined

7 H Shaft, AC Pump Crank, Pin, H Shaft, AC 

Material Pump Crank, 

Pin, Material

3 H Balance, AC Pump Crank, H Balance, AC 

Washed Pump Crank, 

Washed

4 H Balance, AC Pump Crank - H Balance, AC 

Deburred Pump Crank

5 H Balance, AC Pump Crank - H Balance, AC 

Machined Pump 

CrankMachined

Design Profit®
Copyright 2005© Munro & Associates, Inc.
H AC Systems

Level Symbol Name Number

6 H Balance, AC Pump Crank - H Balance, AC 

Stamped Pump 

CrankMachinedStamped

7 H Balance, AC Pump Crank H Balance, AC 

Material Pump Crank 

Material

3 H Rubber Bushing, On Post H Rubber 

Bushing, On 

Post

2 H Gasket, AC Pump H Gasket, AC 

Pump

3 H Gasket, AC Pump Material H Gasket, AC 

Pump Material

2 H Pump Transfer Guide H Pump 

Transfer 

Guide

3 H Pump Transfer Guide H Pump 

Material Transfer Guide 

Material

#

0 H Bolt AC Compressor H Bolt AC 3

Compressor

Design Profit®

Copyright 2005© Munro & Associates, Inc.
Material Piece Cost

Commodity 

Pricing

1

1

1 Aluminum 

A380

1 Aluminum 

A380

1

1

Page 

Qty Material

1

1

1 PMP Plastic 

Metal Plastic

1

1

1 Steel - 1008

3

2

1

1

1

1

1

1

1

1

1

1 3.41 11 $12.30 1 $0.40 1 $1.29 1 $0.92 1 $0.92 1 $0.92 1 $0.84 1 $0.15 1 $2.33 1 $0.07 1 $0.07 2 $0.00 2 $0.06 1 $0.02 1 $0.02 1 $0.70 1 $0.70 1 $0.33 1 $1.18 1 $0.05 1 $0.07

47 $0.01

61 $0.01 18 $0.32 1 $0.32 1 $0.37 1 $0.02
1 $0.47 2 $0.02 1 $0.15 1 $1.30 1 $0.02 2 $0.11 1 $1.92 1 $0.18

57 $0.01

28 $0.01 1 $2.25 1 $1.85

1

1 Galvinized 

Steel - G60

41

1

1

1

1

H AC Board 2 Bare FR41 $2.64

BOTTOM SMT

RHM. 002AUTR-ND6 $0.29

541-1. 0XTR-ND3 $0.03

Capacitors 19 $0.01

Resistors 19 $0.01

TOP SMT

PCE3155TR-ND1 $0.32

PCE3155TR-ND1 $0.32

PCE3155TR-ND1 $0.32

IR2113SPBFC T-ND-11 $1.15
IR2113SPBFC T-ND-1 1 $1.15

IR2113SPBFC T-ND-1 1 $1.15

TLV2464AIPW 1 $1.48

BSS84CT-ND 1 $0.06

HVCB1206T21 00MFICT-ND 3 $2.80

HMC1/8200MK R-ND 4 $0.51

CRCW201030 0RFKTF-ND 2 $0.09

MA2Q70500L CT-ND 3 $0.29

Capacitors 14 $0.01

Resistors 36 $0.01

THRU HOLE

H AC Board 2 Connector - 2 pin 1 0.15

H AC Board 2 Connetor - 4 pin (blade) 1 0.2

SAM1111-22-ND 1 1.85

1

1 Aluminum - 

30xx

1

1

6 Commodity 

Pricing

6

1

4

1

1

1

PMP Plastic 

Metal Plastic

Page 

Qty Material 1 1

11

Commodity 

Pricing

Commodity 

Pricing

1

1 Steel - 1040 6 Molded 

Magnet

1

178 Steel - 1008

1

1

1

1

1

1

1 Commodity

Pricing

Page 

Qty Material 2 Commodity 

Pricing

2 Commodity 

Pricing

1

1

1

1

1

1 Steel - 1018 1

1

1

1

1

1

Page 

Qty Material

1

1

1 Commodity 

Pricing

1

1 Steel Roll 

Formed

1 Aluminum - 

380

1 Aluminum - 

380

Commodity 

Pricing

Page 
Weight

$0.00

$0.13

$111.80

$100.48

$99.88

Aluminum 

A380

Aluminum 

A380

1 of 14

Piece Cost

1 3.41 11 $12.30 1 $0.40 1 $1.29 1 $0.92 1 $0.92 1 $0.92 1 $0.84 1 $0.15 1 $2.33 1 $0.07 1 $0.07 2 $0.00 2 $0.06 1 $0.02 1 $0.02 1 $0.70 1 $0.70 1 $0.33 1 $1.18 1 $0.05 1 $0.07

47 $0.01

61 $0.01 18 $0.32 1 $0.32 1 $0.37 1 $0.02
1 $0.47 2 $0.02 1 $0.15 1 $1.30 1 $0.02 2 $0.11 1 $1.92 1 $0.18

57 $0.01

28 $0.01 1 $0.00 1 $0.00 1

6 Commodity $0.29 3 Commodity $0.03

19 Commodity $0.01

19 Commodity $0.01 1 Commodity $0.32 1 Commodity $0.32 1 Commodity $0.32 1 Commodity $1.15
1 Commodity $1.15 1 Commodity $1.15 1 Commodity $1.48 1 Commodity $0.06 3 Commodity $2.80 4 Commodity $0.51 2 Commodity $0.09 3 Commodity $0.29

14 Commodity $0.01

36 Commodity $0.01

1 Commodity 0.15 1 Commodity 0.2 1 Commodity 1.85

Aluminum - 

30xx

$0.38

7 of 14

Piece Cost

$0.02

$0.05

$0.05

$4.80

$0.00

$3.35

1 Aluminum

8 of 14

Piece Cost

$0.42

Steel - 1018

Steel - 1040

9 of 14

Piece Cost

Steel - 1008

$0.62

$0.41

$0.18

14 of 14
Piece Cost 

(Total)

0.4270 lb

0.0780 lb

13.4130 lb

5.5046 lb

$5.06

$5.06

$5.06

$5.06

$5.06

Weight

$0.30

$0.01

$0.01

$0.54

$0.09

$0.09

$0.15

$0.03

$1.50

$1.00

$1.25

$0.40

$0.55

$40.38

$40.38

$40.38

$36.28

3.41

$12.30

$0.40

$1.29

$0.92

$0.92

$0.92

$0.84

$0.15

$2.33

$0.07

$0.07

$0.00

$0.06

$0.02

$0.02

$0.70

$0.70

$0.33

$1.18

$0.05

$0.07

$0.01

$0.01

$0.32

$0.32

$0.37

$0.02
$0.47

$0.02

$0.15

$1.30

$0.02

$0.11

$1.92

$0.18

$0.01

$0.01

$0.00

$0.00

$0.07

$0.07

$0.02

$48.61

$24.97

$24.97

$24.97

$22.77

$2.64
$0.15

$0.20

$1.85

$0.29

$0.29

$0.29

$0.29

$3.87

$0.02

$0.01

$0.02

$0.28

$0.28

Weight

$0.05

$0.05

0.0031 lb

0.0029 lb

3.9008 lb

$0.00

$0.00

$0.00

$0.00

$0.86

$0.86

$0.86

$0.86

$0.86

$0.86

$2.43

Weight

$0.02

$0.01

$0.12

$0.11

$0.11

$0.11

$0.01

$0.01

$0.01

$0.01

$0.27

$0.27

$0.27

Weight

$0.27

$0.27

$0.03

$0.62

$0.41

0.0930 lb
Weight (Total)

$0.00

$0.26

$111.80

$100.48

5.1979 lb $99.88

4.3755 lb

4.3755 lb

4.3755 lb

4.3755 lb

4.3755 lb

Piece Cost 

(Total)

0.0046 lb

0.0040 lb

0.0040 lb

0.1214 lb

0.0914 lb

0.0914 lb

0.0100 lb

0.0137 lb

0.2579 lb

0.1460 lb

0.2271 lb

0.0340 lb

(Total)

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb
0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

$0.29

$0.03

$0.01

$0.01

$0.32

$0.32

$0.32

$1.15
$1.15

$1.15

$1.48

$0.06

$2.80

$0.51

$0.09

$0.29

$0.01

$0.01

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.3050 lb $0.38

0.3042 lb

0.3042 lb

Piece Cost 

(Total)

0.0004 lb

0.0004 lb

0.0000 lb $0.22

$0.05

$0.05

$4.80

2.3532 lb $0.00

0.7620 lb

0.0452 lb

1.3172 lb

0.0074 lb

1.0394 lb $3.35

0.7463 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.2771 lb

Piece Cost 

(Total)

0.0080 lb

0.0000 lb

0.1306 lb $0.42

0.1302 lb

0.1263 lb

0.0000 lb

0.0000 lb

0.0039 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

Piece Cost 

(Total)

0.0000 lb

0.0000 lb

0.0003 lb

0.0252 lb $0.62

0.0000 lb

0.1156 lb $0.41

0.0000 lb

$0.53
0.4270 lb

0.1560 lb

13.4130 lb

5.5046 lb

$5.06

$5.06

$5.06

$5.06

$5.06

Weight (Total)

$0.30

$0.01

$0.01

$0.54

$0.09

$0.09

$0.45

$0.06

$1.50

$1.00

$1.25

$0.40

$0.55

$40.38

$40.38

$40.38

$36.28

$3.41

$24.47

$12.30

$0.40

$1.29

$0.92

$0.92

$0.92

$0.84

$0.15

$2.33

$0.07

$0.07

$0.00

$0.12

$0.02

$0.02

$0.70

$0.70

$0.33

$1.18

$0.05

$0.07

$0.47

$0.61

$8.40

$2.54

$0.32

$0.37

$0.02
$0.47

$0.04

$0.15

$1.30

$0.02

$0.22

$1.92

$0.18

$0.57

$0.28

$2.25 $2.25

$1.85 $1.85

$0.07

$0.07

$0.08

$48.61

$24.97

$24.97

$24.97

$22.77

$2.64

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb
0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

$0.15

$0.20

$1.85

$0.29

$0.29

$0.29

$0.29

$23.22

$0.12

$0.01

$0.08

$0.28

$0.28

Weight (Total)

$0.05

$0.05

0.0031 lb

0.0029 lb

3.9008 lb

$0.00

$0.00

$0.00

$0.00

$0.86

$0.86

$0.86

$0.86

$0.86

$0.86

$2.43

Weight (Total)

$0.04

$0.02

$0.12

$0.11

$0.11

$0.11

$0.01

$0.01

$0.01

$0.01

$0.27

$0.27

$0.27

Weight (Total)

$0.27

$0.27

$0.03

$0.62

$0.41

0.2790 lb
5.1979 lb

4.3755 lb

4.3755 lb

4.3755 lb

4.3755 lb

4.3755 lb

0.0046 lb

0.0040 lb

0.0040 lb

0.1214 lb

0.0914 lb

0.0914 lb

0.0300 lb

0.0274 lb

0.2579 lb

0.1460 lb

0.2271 lb

0.0340 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb
0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

$1.72 0.0000 lb

$0.10 0.0000 lb

$0.19 0.0000 lb

$0.19 0.0000 lb

$0.32 0.0000 lb

$0.32 0.0000 lb

$0.32 0.0000 lb

$1.15 0.0000 lb
$1.15 0.0000 lb

$1.15 0.0000 lb

$1.48 0.0000 lb

$0.06 0.0000 lb

$8.40 0.0000 lb

$2.04 0.0000 lb

$0.18 0.0000 lb

$0.87 0.0000 lb

$0.14 0.0000 lb

$0.36 0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.3050 lb

0.3042 lb

0.3042 lb

0.0004 lb

0.0004 lb

0.0000 lb

2.3532 lb

0.7620 lb

0.2712 lb

1.3172 lb

1.3172 lb

1.0394 lb

0.7463 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.2771 lb

0.0160 lb

0.0000 lb

0.1306 lb

0.1302 lb

0.1263 lb

0.0000 lb

0.0000 lb

0.0039 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0000 lb

0.0003 lb

0.0252 lb

0.0000 lb

0.1156 lb

0.0000 lb
Page: 1 of 8 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

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

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

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

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

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

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

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

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

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

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

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

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 0 ##### 0 1 1 0.142 #N/A #N/A #N/A #N/A #N/A #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 0.203 #N/A #N/A #N/A #N/A #N/A #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 8 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, HEV, Electrically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 8 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, HEV, Electrically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

D Purchase Part - Commodity ( Value taken from Purchase Part Database)

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 0 $0.00 $0.00 $0.00 $0.00 $0.00

3 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: ----- ----- ----- ----- 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 ----- ----- ----- $0.00 $0.00 $0.00 $0.00 $0.00

Base Cost Impact to Vehicle: $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $0.00

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 8 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0602 (N = New, 06 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Ford Fusion, HEV, Electrically Driven Air Conditioning Compressor Annual Component Volume: Shipping Method:

Component Description: Compressor Assembly - Air Conditioning Part Number: 120301-N0602-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Electrically Versus Mechanically Driven Air Conditioning Compressor

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 8 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/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 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 1 2 10 20 47 940 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 1 2 10 20 47 940 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

File:09000064810ec171.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 8 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/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 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $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 #DIV/0! #DIV/0! #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #DIV/0! -

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0 #DIV/0! #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: 7 of 8 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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 8 Manufacturing Assumption and Quote Summary Print Date:8/30/2012

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 Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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