# 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/A **ir Conditioning Subsy stem** 

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. Scaling Parameter(s) Description**  **Notes** 

### Sub-Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem 

### Total **Packaging 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)** 

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** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 148.86 **$ 23.86** 

**$ 43.32** 

**$ 216.04** 

**$ 1.85** 

**$ 14.57** 

**$ 13.38** 

**$ 5.46** 

**$ 35.25** 

**$**

**-**

**$ 251.30** 

**$**

**-**

**$** 

### SUBSYSTEM ROLL-UP

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 **Scaling Parameter(s) Description Notes**  

### Sub-Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem 

### Total **Packaging 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)** 

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 **Scaling Parameter(s) Description Notes**  

### Sub-Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem 

### Total **Packaging 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)** 

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 **Cy linder 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 COST INFORMATIONItemSubsystemSub-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 **Scaling Parameter(s) Description Notes**  

### Sub-Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem 

### Total **Packaging 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)** 

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 **Cy linder 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 TECHNOLOGY PACKAGE**ItemSubsystemSub-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 **Scaling Parameter(s) Description Notes**  

### Sub-Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem 

### Total **Packaging 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)** 

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/A **ir Conditioning Subsy stem** 

1 **00**

2 **01** 

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### 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 -**  **$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

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**224.32 $**  **238.30 $**  **256.42 $**  **320.15 $**  **293.54 $**  **282.62 $** 

**-**

**$**

**-**

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**-**

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### 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 DESCRIPTIONItemSubsystem



### 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 DESCRIPTIONItemSubsystem



### 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 **Cy linder 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** ItemSubsystemSub-Subsystem



### Material Labor Burden

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**(x1000) Investment** 

**(X1000)** Manufacturing 

# BASE TECHNOLOGY PACKAGE COST INFORMATION

H1 **70** 2 - $

-

$

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### -

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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 DESCRIPTIONItemSubsystem



### 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)** 

- $

-

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-

$

-

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-

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**BS YS** 



# 05 **Cy linder Blocks** 

A1 **01**

B1 **02**

C1 **03**

D1 **04** 

# TECHNO **LOGY PACKAG** ItemSubsystemSub-Subsystem 

### - $

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Material Labor Burden

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-

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-

$ 24.10

$ 19.18

$ 25.92

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$ #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 DESCRIPTIONItemSubsystem



### 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)** 

- $

-

$

-

$

-

$

-

$

-

$

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-

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### J1 **80**

K1 **85**

L1 **90**

M1 **99**

N1 **00**

**SU BS**  **YS** - $

-

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### #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/A **ir Conditioning Subsy stem** 

1 **00**

2 **01** 

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### 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** 

**- $** 

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**69.20 $**  **0.58**

**$ 6.52** 

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**$ 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**  **(e.g. Ford Focus) Total Markup**  **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 -** 

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### 69.20 **$ 0.58** 

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**-**

**$ 83.75** 

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**-**

**$ 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 DESCRIPTIONItemSubsystem



### 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**  **(e.g. Ford Focus) Total Markup**  **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 DESCRIPTIONItemSubsystem



### 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**  **(e.g. Ford Focus) Total Markup**  **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 **Cy linder 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** ItemSubsystemSub-Subsystem



### End Item Scrap SG&A Profit ED&T-R&D

**- $** 

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**#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!** 

### #REF! #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**

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**Packaging Cost**  **(Component / Assembly)**  **Net**

**Component/ Assembly**  **Cost Impact to OEM**  

# BASE TECHNOLOGY PACKAGE COST INFORMATION

**Total Manufacturing**  **Cost (Component/**  **Assembly)**



### H1 **70** 2 **-**

**$**

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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 DESCRIPTIONItemSubsystem



### 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**  **(e.g. Ford Focus) Total Markup**  **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**

**- $** 

-

$

-

$

-

$

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### M1 **99** 2 N1 **00** 2 **SU**

**BS YS** 



# 05 **Cy linder Blocks** 

A1 **01**

B1 **02**

C1 **03**

D1 **04** 

# TECHNO **LOGY PACKAG** ItemSubsystemSub-Subsystem 

### -

**$**

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**#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**

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

**- $** 

-

$

-

$

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**-**

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**69.20 $**  0.58

$ 6.52

$ 5.56

$ 1.89

$ **14.56**

**$**

-

$ **83.75**

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**#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**

**-**

**$**

-

$

-

$

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$

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$

**-**

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-

$

**-**

**$**



### 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 DESCRIPTIONItemSubsystem



### 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**  **(e.g. Ford Focus) Total Markup**  **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**

**- $** 

-

$

-

$

-

$

-

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**-**

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**- $** 

**- $** 

**- $**  

### J1 **80**

K1 **85**

L1 **90**

M1 **99**

N1 **00**

**SU BS**  **YS -**  **$**

-

$

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### #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/A **ir Conditioning Subsy stem** 

1 **00**

2 **01** 

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### 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

**- $** 

**-**

**$**

**-**

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**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 -**  **$**

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**$ 7.82** 

**$ 3.57** 

**$ 20.70** 

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**-**

**$ 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 DESCRIPTIONItemSubsystem



### 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 DESCRIPTIONItemSubsystem



### 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 **Cy linder 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** ItemSubsystemSub-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 DESCRIPTIONItemSubsystem



### 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 **Cy linder Blocks** 

A1 **01**

B1 **02**

C1 **03**

D1 **04** 

# TECHNO **LOGY PACKAG** ItemSubsystemSub-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 DESCRIPTIONItemSubsystem



### 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/A **ir Conditioning Subsy stem** 

1 **00 Assembly of Refrigeration/Air Conditioning Subsystem** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

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**-**

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**-**

**$**

**-**

**$**



### 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** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

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**$**

**-**

**$**



### 4 **05 AC Lines, Receiver Drier and Accumulator** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

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**$**

**-**

**$**

**-**

**$**



### 5 **10 Plugs** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

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**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ System**  **ED&T/R&D (x1000)**  **Investment (X1000)**  **Total Markup Cost**  **(Component/ Assembly)**  **Total**

**Packaging Cost**  **(Component / Assembly)** ItemSubsystem


### 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 TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

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** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

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**-**

**$**

**-**

**$**

**-**

**$**



### 7 **75 Brackets** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

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**$**

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**$**

**-**

**$**

**-**

**$**



### 8 **80 Boltings** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

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**$**

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**-**

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**-**

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**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 9 **85 Sealing Elements** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 10 **97 Vehicle Wiring - Misc** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 11 **99 Miscellaneous** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

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**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 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** 

**$ SUBSYSTEM ROLL-UP** 

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)** ItemSubsystem


### 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 TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

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)** ItemSubsystem


### 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 TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

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 **Cy linder Blocks**  **BASE TECHNOLOGY PACKAGE COST INFORMATION**ItemSubsystemSub-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 TECHNOLOGY PACKAGE COST INFORMATION

Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly) System**  **ED&T/R&D (x1000)**  **Tooling**

**(x1000)**



### A1 **01**

- $

-

$

-

$

**-**

**$**

-

$

-

$

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$

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### -

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**-**

**$** B1 **02**

- $

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-

$

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### -

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**$** C1 **03**

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### -

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**$** D1 **04** #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**

- $

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-

$ #REF! #REF! #REF! **#REF!** 

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

**- $** 

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### #REF! #REF! #REF! **#REF!** E1 **65**

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### -

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**$** F1 **66**

- $

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### -

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**-**

**$** G1 **67**

- $

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### 2

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### -

$

-

$

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**-**

**$** H1 **70**

- $

-

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**-**

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-

$

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### 2

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### -

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**-**

**$** I1 **75**

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### 2

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### -

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**$** J1 **80**

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### 2

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### -

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**-**

**$** K1 **85**

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### 2

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### -

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**-**

**$** L1 **90**

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-

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-

$

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### 2

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### -

$

-

$

-

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**-**

**$** M1 **99**

- $

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-

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### 2

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### -

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**-**

**$** N1 **00**

- $

-

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### 2

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### -

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**$** $ $ **$ $**  $ **$ $**  **$ $**  

### $ **$**

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)** ItemSubsystem


### 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 TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

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 BurdenItemSubsystemSub-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 UPGRADE TO NEW TECHNOLOGY PACKAGE** 

Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly) Investment**  **(X1000) System**  **ED&T/R&D (x1000)**  **Tooling**

**(x1000)**



# 05 **Cy linder 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**

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

-

$

-

$

-

$

-

$

-

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-

$

**-**

**$**



### - $

-

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-

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-

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-

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-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

$

-

$

-

$

**-**

**$** 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)** ItemSubsystem


### 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 TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

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)

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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/A **ir Conditioning Subsy stem** 

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# SYSTEM & SUBSYSTEM DESCRIPTION

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# 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)** 



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### 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 DRAFTItemSubsystem 

# 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 DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION



# 05 **Cy linder Blocks** ItemSubsystemSub-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** 



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### 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 DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

**SU BS**  **YS**ItemSubsystemSub-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)** 



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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 **Cy linder Blocks** 

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-

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-

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-

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-

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### - $

-

$

-

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-

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**-**

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-

$

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**- $**  

### 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 DRAFTItemSubsystem 

# 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/A **ir Conditioning Subsy stem** 

1 **00**

2 **01**

3 **02**

4 **05**

5 **10**ItemSubsystem 

# 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 DRAFTItemSubsystem 

# 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 DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION



# 05 **Cy linder Blocks** ItemSubsystemSub-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 DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

**SU BS**  **YS**ItemSubsystemSub-Subsystem 

# TECHNO **LOGY PACKAG**  **Investment(X1**

**000)**



# 05 **Cy linder 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 DRAFTItemSubsystem 

# 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/A **ir Conditioning Subsy stem** 

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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**

MarkupAssembly 

### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-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. 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: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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**

MarkupAssembly 

### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-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 W ire Harness - HEV Underbody (14B322) 12 03 97

- N0502

- 01 1 NA 1 Wi ring and VO connection assembly labor captured in Power Distribution System as part of HV wire harness. 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### B LV W ire 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 W ire) offset by Field Coil Electrical Connection on Base Mechanical Connector (2 Pin Low Gauge W ire) 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 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/A **ir Conditioning Subsy stem** 

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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-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)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-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 W ire Harness - HEV Underbody (14B322) 12 03 97

- N0502

- 01 1 NA 1 Wi ring and VO connection assembly labor captured in Power Distribution System as part of HV wire harness. 

### Investment **(X1000) Tooling**  **(x1000)**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



### B LV W ire 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 W ire) offset by Field Coil Electrical Connection on Base Mechanical Connector (2 Pin Low Gauge W ire)



### 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** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

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**$**

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**$**



### - $

-

$

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-

$

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$

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### - $

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-

$

-

$

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$

-

$

**-**

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-

$

**-**

**$**

**-**

**$** 

# 120300 Refrigeration/A **ir Conditioning Subsy stem** 

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 INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

### 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**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE **PARAMETERS**

MarkupAssembly 

### 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. 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: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&DSub-Subsystem



### Part Number 

# BASE TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

### 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**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE **PARAMETERS**

MarkupAssembly 

### 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 W ire) offset by Field Coil Electrical Connection on Base Mechanical Connector (2 Pin Low 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**
Mechanical Connector (2 Pin Low Gauge W ire)



### 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/A **ir Conditioning Subsy stem** 

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 NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem 

# 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 DRAFTSub-Subsystem



### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem 

# 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 W ire) offset by Field Coil Electrical Connection on Base Mechanical Connector (2 Pin Low 

### Investment **(X1000) Tooling**  **(x1000)**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**
Mechanical Connector (2 Pin Low Gauge W ire)



### 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

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

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**-**

**$**

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**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$** 

# 120300 Refrigeration/A **ir Conditioning Subsy stem** 

1 **00 Assembly of Refrigeration/Air Conditioning Subsystem** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 2 **01 AC Compressor** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 3 **02 Condenser** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**Sub-Subsystem



### Part Number 

# BASE TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

### 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**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE **PARAMETERS**

MarkupAssembly 

### 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&DSub-Subsystem



### Part Number 

# BASE TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

### 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**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE **PARAMETERS**

MarkupAssembly 

### 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/A **ir Conditioning Subsy stem** 

1 **00 Assembly of Refrigeration/Air Conditioning Subsystem** 

2 **01 AC Compressor** 

3 **02 Condenser** Sub-Subsystem



### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem 

# 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 DRAFTSub-Subsystem



### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem 

# 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/A **ir Conditioning Subsy stem - A**  **C 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 MAQSSubassemblyComponentSub-Subsystem 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **Electric Air Conditioning Compressor: AC Synchronous, Permanent**

**Magnet, 3 Phase, 6 Pole Motor**ItemSubsystem 

# 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 INFORMATIONQTY/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&DSubassemblyComponentSub-Subsystem 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **Electric Air Conditioning Compressor: AC Synchronous, Permanent**

**Magnet, 3 Phase, 6 Pole Motor**ItemSubsystem 

# 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 INFORMATIONQTY/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/A **ir Conditioning Subsy stem - A**  **C 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 MAQSSubassemblyComponentSub-Subsystem 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **Electric Air Conditioning Compressor: AC Synchronous, Permanent**

**Magnet, 3 Phase, 6 Pole Motor**ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/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 DRAFTSubassemblyComponentSub-Subsystem 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **Electric Air Conditioning Compressor: AC Synchronous, Permanent**

**Magnet, 3 Phase, 6 Pole Motor**ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### 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 Load **124 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 COSTS MANUFACTURING RATES**  **Electrically Versus Mechanically Driven Air Conditioning Compressor**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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 Load **107 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 Load **118 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 Not Applicable CNC Operator CNC Machining, LC, Automatic Load **141 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** 20 4C H Midplate 120301-N0602-115-2 **1** Machine T1 Assembly, Mark-up Applied @ Bottom. Not Applicable CNC Operator CNC Machining, LC, Automatic Load **141 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 Load **105 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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America**  **North America**

**FOB Ship Point 47**  **450,000 1**  **450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Electrically Versus Mechanically Driven Air Conditioning Compressor**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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 $37.27**  **1 Material**  **Labor Burden**  **TMC Scrap**  **SG&A Profit**  **ED&T 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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### 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 all equal same value otherwise there is a computation**  **error.**



### 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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**

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

**$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 4C H Midplate 120301-N0602-115-2

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: R** **e f** **e r** **e n** **c e** **#** 

### 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** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Projected Operating Pattern **Minimum Calculated Cycles Time**

**MANUFACTURING ASSUMPTIONS Manufacturing Costs x Quantity**  **Project Process Requirement Process Information**  **Gross Mark-up Costs x Quantity 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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### 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 COSTS MANUFACTURING RATES**  **Electrically Versus Mechanically Driven Air Conditioning Compressor**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**



## 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 Sub

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 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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America**  **North America**

**FOB Ship Point 47**  **450,000 1**  **450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Electrically Versus Mechanically Driven Air Conditioning Compressor**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**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 all equal same value otherwise there is a computation**  **error.**

**Net Cost Impact to Vehicle: $22.71** 

**Packaging Cost per**  **Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### 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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**

**$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**  **Project Process Requirement Process Information**  **Gross Mark-up Costs x Quantity 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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Projected Operating Pattern **Minimum Calculated Cycles Time**

**MANUFACTURING ASSUMPTIONS Manufacturing Costs x Quantity**  **Project Process Requirement Process Information**  **Gross Mark-up Costs x Quantity 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

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# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### 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 COSTS MANUFACTURING RATES**  **Electrically Versus Mechanically Driven Air Conditioning Compressor**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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. 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** 15 8A H AC Motor Stator Top 120301-N0602-557 **1** Injection Mold @ 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 Sub

Assembly.



### 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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America**  **North America**

**FOB Ship Point 47**  **450,000 1**  **450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Electrically Versus Mechanically Driven Air Conditioning Compressor**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### 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 all equal same value otherwise there is a computation**  **error.**



### 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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America**  **North America**

**FOB Ship Point 47**  **450,000 1**  **450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Electrically Versus Mechanically Driven Air Conditioning Compressor**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**



### 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: R** **e f** **e r** **e n** **c e** **#** 

### 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** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**

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

**$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 8A H AC Motor Stator Top 120301-N0602-557

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: R** **e f** **e r** **e n** **c e** **#** 

### 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** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Projected Operating Pattern **Minimum Calculated Cycles Time**

**MANUFACTURING ASSUMPTIONS Manufacturing Costs x Quantity**  **Project Process Requirement Process Information**  **Gross Mark-up Costs x Quantity 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: R** **e f** **e r** **e n** **c e** **#** 

### 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** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Projected Operating Pattern **Minimum Calculated Cycles Time**

**MANUFACTURING ASSUMPTIONS Manufacturing Costs x Quantity**  **Project Process Requirement Process Information**  **Gross Mark-up Costs x Quantity 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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### 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 Into Categories with Quantity per Assembly Taken into Account **TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Electrically Versus Mechanically Driven Air Conditioning Compressor** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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 Sub

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.

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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Electrically Versus Mechanically Driven Air Conditioning Compressor** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### 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 all equal same value otherwise there is a computation**  **error.**



### 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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Electrically Versus Mechanically Driven Air Conditioning Compressor** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**



### 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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**

**$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 

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

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**  **$1.18** MOSFET 120301-N0602-375
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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### 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 Into Categories with Quantity per Assembly Taken into Account **TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Electrically Versus Mechanically Driven Air Conditioning Compressor** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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 Sub

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. 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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Electrically Versus Mechanically Driven Air Conditioning Compressor** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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 120301-N0602-351 **1** SAM1111-22-ND S **$0.00** $1.85 **$0.00 $1.85**  **$1.85**

Header - 22 position 120301-N0602-351 SAM1111-22-ND

**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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### 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 all equal same value otherwise there is a computation**  **error.**



### 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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Electrically Versus Mechanically Driven Air Conditioning Compressor** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**



### 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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**

**$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 

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

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

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# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$1.48 $0.06**  **$8.40 $2.04**  **$0.18 $0.87**  **$0.14 $0.36**  **$0.00 $0.15**  **$0.20 $1.85**  9C Header - 22 position 120301-N0602-351

**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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 4 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### 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 COSTS MANUFACTURING RATES**  **Electrically Versus Mechanically Driven Air Conditioning Compressor**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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 Sub

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.

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**  **$6.05 1** 



### 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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America**  **North America**

**FOB Ship Point 47**  **450,000 1**  **450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Electrically Versus Mechanically Driven Air Conditioning Compressor**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**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 T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **N u** **m b** **e r** **o f** **P a** **r t** **s p** **e r** **P a** **l l** **e t** **/ S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n****** 

### PACKAGING CALCULATIONS: **3** 

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



### 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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### 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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**

**$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**  **Project Process Requirement Process Information**  **Gross Mark-up Costs x Quantity 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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Projected Operating Pattern **Minimum Calculated Cycles Time**

**MANUFACTURING ASSUMPTIONS Manufacturing Costs x Quantity**  **Project Process Requirement Process Information**  **Gross Mark-up Costs x Quantity 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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### 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 Into Categories with Quantity per Assembly Taken into Account **TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Electrically Versus Mechanically Driven Air Conditioning Compressor** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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 Sub

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. 

### 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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Electrically Versus Mechanically Driven Air Conditioning Compressor** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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 all equal same value otherwise there is a computation**  **error.**



### 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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### 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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Electrically Versus Mechanically Driven Air Conditioning Compressor** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**

**$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!** 

- 

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**



## 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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$0.50 $0.16**  **$0.20 $0.40**  **$0.06 $0.10**  **$0.04 $0.24**  **$0.01 $0.14**  **$0.06 $0.08**  6A Wire Harness X-mas tree snap 120301-N0602-466 **$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

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# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

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# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### 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 Into Categories with Quantity per Assembly Taken into Account **TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Electrically Versus Mechanically Driven Air Conditioning Compressor** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Electrically Versus Mechanically Driven Air Conditioning Compressor** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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 Sub

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**

**$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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### 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 all equal same value otherwise there is a computation**  **error.**



### 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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Electrically Versus Mechanically Driven Air Conditioning Compressor** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**



### 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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**

**$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 

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$0.00 $0.00**  **$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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 6 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark-up**  **Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### 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 Into Categories with Quantity per Assembly Taken into Account **TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Electrically Versus Mechanically Driven Air Conditioning Compressor** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **North America 47**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  **Di ffe**  **ren tial Qu**  **ote (Quote S um**  **ma ry includes costing for both T**  **ech nol**  **ogy P ackag**  **es)**

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 Sub

Assembly.

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 (W eeks/Year): OEM Plant Location:

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark-up**  **Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Electrically Versus Mechanically Driven Air Conditioning Compressor** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **North America 47**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  **Di ffe**  **ren tial Qu**  **ote (Quote S um**  **ma ry includes costing for both T**  **ech nol**  **ogy P ackag**  **es)**

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 120301-N0602-80 **1** S **$0.00** $8.64 **$0.00 $8.64**  $330,000 **$8.64**

Potting Gel 120301-N0602-80 $330,000
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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### 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 all equal same value otherwise there is a computation**  **error.**



### 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 (W eeks/Year): OEM Plant Location:

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark-up**  **Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Electrically Versus Mechanically Driven Air Conditioning Compressor** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **North America 47**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  **Di ffe**  **ren tial Qu**  **ote (Quote S um**  **ma ry includes costing for both T**  **ech nol**  **ogy P ackag**  **es)**



### 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:**R e** **f e** **r e** **n c** **e #**  

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**

**$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 **M** anual install o-ring & scroll thrust seal to rear scroll, load rear scroll and housing to pallet, S#2 **M** anual 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 **M** anual load balance crank and shaft, auto press, (gravity fed transfer) S#2 **M** anual 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, **M** anual 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 **M** anual 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 **M** anual 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 **M** anual 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 

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

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 **M** anual 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 **M** anually 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 **M** anually 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 **M** anual 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 **M** anually manipulate coil wires into terminal block interface assemble and crimp 4 locations, S#8 **M** anually 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 **M** anually 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# **M** anual load connector mount bracket/potting gel seal, semi automated run down, S #15/16 Auto Functional Test, Date Code and pack. (x1 **M** ) **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** 

**$0.00** 3A H Nut, To Stud, Rear Scroll 120301-N0602-052

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:**R e** **f e** **r e** **n c** **e #**  

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$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 $8.64**  29A Potting Gel 120301-N0602-80
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:**R e** **f e** **r e** **n c** **e #**  

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

# Sy **mbol Name**



# 0 **H Bracket A C Compressor**  **Mount to Block**

**1 H Bracket A**  **C Compressor**

**Deburred**

**2 H Bracket A**  **C Compressor Machined** 

**3 H Bracket A**  **C Compressor**

**Casting Trimmed**

**4 H Bracket A**  **C Compressor**

**Casting**

**5** H Bracket Compressor

Material

0 H Bolt AC Compressor Bracket

**0 H Electric A**  **C Compressor**

**As sembly** 

**1 H Housing, Coil, and** 

**Electronics A**

**sm.**

**2 H Housing A**  **sm., Potted Electronics** 

**3 H Housing, Compressor** 

**Motor, Washed, Final Part**

# Level **Sy mbol 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 A**

**sm.**

**4 H Plate Terminal Block,**  **Passthrough A**

**sm**

**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 A**  **C PCB 1 preassembled**

**4 H A**  **C PCB 1 w all**

**components**

**5 H A**  **C PCB 1 w Thru Hole**

**mntd**

**6**

**7**

**7**



# Level

# Level

**7**

# 6

6

**3 H Bracket A**  **C PCB**

**1connector**



# Level **Sy mbol Name** 

4 H Bracket AC PCB 1connector-Blank

3 H Screw IGBT to base

**3 H A**  **C PCB 2 preassembled**

**4 H A**  **C PCB 2 wo metal base**

**5 H A**  **C PCB 2 w all**

**components**

# 6

**7**



# Level

# 7

7

7

**4 H A**  **C PCB 2 Base plate assy**

**5 H A**  **C PCB 2 Base plate**

**assy -W**  **ashing**

**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 A**  **ssembly**

# 3 **H Cover Compressor Housing** 

**4** H Cover Compressor Housing

3 H Sticker, W arning,

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 A**  **C Compressor Motor**

**Stator A sm** 

**2 H A**  **C Motor Stator Stack, Machined** 

**3 H A**  **C Motor Stator Stack**



# Level **Sy mbol Name** 

**4 H A**  **C Motor Stator Plates - w/A**  **lignment Notch & Hol**

**5** H AC Motor Stator Plates - w/

Notch & Holes Materi

**4 H A**  **C Motor Stator Plates -**

**w/1 Notch no holes**

**5** H AC Motor Stator Plates -

w/Notch & No Holes Mate

# 4 **H A C Motor Stator Plates -**  **No Notch**

**5** H AC Motor Stator Plates - No

Notch Material

**4 H A**  **C Motor Stator Plates - 3 notches - no holes** 

**5** H AC Motor Stator Plates, 3

notches, no holes - ma

**4 H A**  **C Motor Stator Plates - 3 notches plus holes** 

**5** H AC Motor Stator Plates - w/3

Notche & Holes Mate

**2 H A**  **C Motor Stator Insulator Base** 



# Level **Sy mbol Name** 

3 H AC Motor Stator Base Material

**2 H A**  **C Motor Stator Insulator**

**Top 3**  H AC Motor Stator Top

Material

2 H AC Motor Stator Insulator

Liners

2 H AC Motor Stator W indings

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 W rap

2 H AC Motor Stator W inding

Spacers

**1 H A**  **C Motor Stator Wire**

**Retainer Cap**

**2** H AC Motor Stator Retainer Material

**1 H Scroll Impeller A**  **sm.**



# Level **Sy mbol Name** 

**2 H A**  **C Motor Magnets and Shaft A**  **sm.**

**3 H A**  **C Motor Shaft**

**4 H A**  **C Motor Shaft, Machined**

**5** H AC Motor Shaft, Material

**3 H A**  **C Motor Rotor A sm,**  **Riveted**

**4** H AC Motor Rivets

**4 H A**  **C Motor Weight #1**

# 5 **AC Motor Weight #1**  **Deburred**

**6**

**7**

**4 H A**  **C Motor Rotor Endplate**

**#1**

**5 H A**  **C Motor Rotor Endplate**

**#1 Stamped**

**6**

**4 H A**  **c Motor Rotor Plate A sm** 

**5 H A**  **C Motor Rotor Plate**



# Level

6

4 H AC Motor Magnets

**4 H A**  **C Motor Rotor Endplate**

**#2**

**5 H A**  **C Motor Rotor Endplate**

**#2 Stamped**

**6**

**4 H A**  **C Motor Weight #2**

# 5 **AC Motor Weight #2**  **Deburred**

**6**

**7**

**2 H Midplate A**  **sm.**

**3 H Midplate, Washed** 

**4 H Midplate, Deburred** 

**5 H Midplate, Machined** 

**6**

**7**



# Level **Sy mbol Name** 

3 H Bearing, AC Pump

3 H Dowel Pin, Midplate Asm.

3 H Dowel Pin, Small, Midplate

Asm

**2 H A**  **C Pump, Crank A sm.** 

**3 H Shaft, A**  **C Pump Crank,**

**As m** 

**4 H Shaft, A**  **C Pump Crank,**

**Wa shed** 

**5 H Shaft, A**  **C Pump Crank,**

**Machined**

# 6

**4 H Shaft, A**  **C Pump Crank, Pin**

**5 H Shaft, A**  **C Pump Crank,**

**Pin, Deburred**

**6**

**7**

**3 H Balance, A**  **C Pump Crank,**

**Wa shed** 

**4 H Balance, A**  **C Pump Crank - Deburred**  **5 H Balance, A**  **C Pump Crank -**

**Machined**



# Level

**6**

**7**

3 H Rubber Bushing, On Post

**2 H Gasket, A**  **C 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 A**  **sm.**

**2 H Rear Scroll A**  **sm, Scroll Housing** 

**3 H Rear Scroll** 

**4 H Rear Scroll, Machined** 

**5 H Rear Scroll, Trimmed** 

**6**

**7**



# Level **Sy mbol 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 **Sy mbol 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,** 

**Wa shed** 

**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 A**  **sm., Scroll Impellar** 



# Level **Sy mbol Name** 

3 H Bolt, Scroll Housing, Impellar

3 H O-ring, Bolt, Scroll Impellar

**2 H Plug, Large, Rear Scroll,** 

**As m.** 

**3** H Plug, Large, Rear Scroll

3 H O-ring, Large Plug

**2 H Pressure Relief A**  **sm, 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 A**  **sm, Scroll Housing** 

**3 H ImpellerScroll** 

**4 H Impeller Scroll, A**  **nodize**

**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 A C**  **Compressor Mount to**  **Block H Bracket A**  **C**

**Compressor Deburred**  **H Bracket A C** 

**Compressor Machined** 

H Bracket Compressor

H Bolt AC Compressor Bracket **H Electric A C**  **Compressor As**  **sembly H Housing,** 

**Coil, and Electronics**  **As m.**  **H Housing**

**As m., Potted**  **Electronics**

# H Housing, Compressor

**H Housing, Compressor Motor, Casting** 

H Housing, Compressor Motor,

Alum Mtl

H Plate Terminal Block,

# H A **C PCB 1 w Thru Hole**

**H A C PCB 1 w SMT mntd** 

H AC Board 1 Bare FR4

**H A C board 1 BOTTOM SIDE** 

**8** IC H8 MCU FLASH 256K 100TQFP 8 IC - OP Amp

8 IC - Voltage Regulator



# Sy **mbol 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



# Sy **mbol Name**

**H A C board 1 TOP SIDE -**  **SURFA CE 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 A **C PCB 2 w thru hole**

**mnted**

**H A C PCB 2 w SMT mnted** 

**8** H AC Board 2 Bare FR4

**8 H A**  **C Board 2 BOTTOM SIDE**

**- SURFA CE MOUNT** 

**9** Chip Resistor - Surface Mount

9 Chip Resistor

9 Capacitors

9 Resistors

**8 H A**  **C Board 2 TOP SIDE -**

**SURFA CE MOUNT** 

**9** Aluminum Capacitor - SM

9 Aluminum Capacitor - SM



# Sy **mbol 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

**H A C PCB 2 Base plate** 

**H A C PCB 2 Base plate**  **assy -Machining** 



# Sy **mbol Name**

H AC PCB 2 Base plate assy-Blank

**H Cover As**  **sembly ,** 

# H Screw AC Comp Cover H O-ring, Outer, AC Compressor H O-ring, Inner, AC Compressor **H A C**  **Compressor Motor Stator**  **As m**  **H A C Motor** 

**Stator Stack, Machined** 

H AC Motor Stator Plates - w/ Notch & Holes Materi

H AC Motor Stator Plates - w/Notch & No Holes Mate

# H AC Motor Stator Plates - No

H AC Motor Stator Plates, 3 notches, no holes - ma

H AC Motor Stator Plates - w/3 Notche & Holes Mate

**H A C Motor**  **Stator Base**



# Number

**H A C Motor**  **Stator Top**

H AC Motor Stator Insulator Liners H AC Motor Stator Wi ndings 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 W rap

H AC Motor Stator W inding Spacers **H A C Motor**  **Stator Wire Retainer Cap**  H AC Motor

Stator Retainer Material **H Scroll Impellar A** 

**sm.**



# Number

**H A C Motor**  **Magnets and Shaft A**  **sm.**

H AC Motor Shaft, Material

# AC **Motor Weight #1**

**H A C Motor Weight 1**  **Trimmed**

**AC Motor Weight #1 Casting** 

**8** AC Motor W eight #1 Material

**H A C Motor Rotor Endplate** 

H AC Motor Rotor Endplate #1 Material

**H A C Motor Rotor Plate** 



# Sy **mbol Name**

AC Motor Rotor Plate Material

**H A C Motor Rotor Endplate** 

H AC Motor Rotor Endplate #2 Material

# AC **Motor Weight #2**

**H A C Motor Weight 2**  **Trimmed**

**AC Motor Weight #2 Casting** 

**8** AC Motor W eight #2 Material

**H Midplate As**  **m.**

**H Midplate, Machined**

**H Midplate, Trimmed**

**H Midplate, Diecast**

**8** H Midplate, Material



# Number

**H A C Pump,**  **Crank A sm.** 

**H Shaft, A C Pump Crank,** 

# H Shaft, AC Pump Crank,

Material

**H Shaft, A C Pump Crank,** 

**H Shaft, A C Pump Crank,**  **Pin, Machined**

H Shaft, AC Pump Crank, Pin,

Material

**H Balance, A C Pump Crank -** 



# Sy **mbol Name**

**H Balance, A C Pump Crank -**  **Stamped**

H Balance, AC Pump Crank

Material

**H Gasket, A C**  **Pump**

**H Pump Transfer**  **Guide**

# H O-ring, Outer, AC Compressor H O-ring, Inner, AC Compressor **H Scroll Housing A** 

**sm. H Rear Scroll** 

**As m, Scroll**  **Housing**

**H Rear Scroll, Trimmed**

**H Rear Scroll, Diecast**

H Rear Scroll, Aluminum



# Number

**H Check Valve, Rear Scroll,**

H Check Valve, Rear Scroll, Steel

# H Check Valve Support, **Scroll Valve, Stamped**

H Check Valve Support, Scroll Valve, Steel

H Restrictor, Rear Scroll, Oil



# Number

**H Spacer, Scroll**  **Housing, Painted** 

# H Spacer, Scroll Housing,

**H Scroll Housing** 

**H Scroll Housing, Die Cast**

H Scroll Housing, Material

**H Bolt and O-ring A**  **sm., Scroll**  **Impellar**



# Number

**H Plug, Large, Rear Scroll,**  **As m.** 

**H Pressure Relief A**  **sm, Rear Scroll** 

# H Stud, Rear Scroll To Stud,

**H Impeller Scroll A**  **sm, Scroll**  **Housing**

**H Impeller Scroll, Machined**

**H Impeller Scroll, Trimmed**

**H Impeller Scroll, Diecast**



# Sy **mbol Name**

8 H Impeller Scroll, Aluminum

H Bolt, Scroll Housing, M8 x 40 H Bolt AC Compressor

# Qty **Material**



# 1

**1**

**1**

**H Bracket A C**  **Compressor Casting**  **Trimmed H Bracket A**  **C**

**Compressor Casting**  H Bracket

Compressor Material 2 Commodity Pricing

**1**

**1**

**1**

**H Housing, Compressor**  **Motor, Wa**  **shed, 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,

TerminalPassthroughStamping **H Terminal Block,**  **Passthrough As**  **m. H Plate** 

**Terminal Block,**  **Passthrough As**  **m** 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 A C PCB 1**  **preassembled H A**  **C PCB 1 w**

**all components**  **H A C PCB 1 w** 

**Thru Hole mntd**  **H A C PCB 1 w**  **SMT mntd** H AC Board 1

Bare FR4 **H A C 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 A C board 1** 

**TOP SIDE - SURFA**  **CE MOUNT**  PCE3155TRNDPCE3146TRNDPCE3156TRND ST70-27MF

# "2SC3303-O (T6L1,NQ)-ND" BZX84C27- FDITR-ND "TE85L,Q,M"

NCV4274ADT33RKGOSTRND 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 A C**  **PCB 1connector** 



# Number **Qty**

H Bracket AC PCB1connectorBlank H Screw IGBT to base **H A C PCB 2**  **preassembled H A**  **C PCB 2**

**wo metal base H A**  **C PCB 2 w**

**all**

# components **H A C PCB 2 w**  **thru hole mnted**  **H A C PCB 2 w** 

**SMT mnted** H AC Board 2

Bare FR4 **H A C Board 2**  **BOTTOM SIDE -**  **SURFA CE**  **MOUNT** RHM.

002AUTR-ND 541-1. 0XTR-ND Capacitors

Resistors

**H A C Board 2**  **TOP SIDE - SURFA**  **CE MOUNT**  PCE3155TRNDPCE3155TRND



# Number

PCE3155TRND IR2113SPBFC T-ND-1 IR2113SPBFC T-ND-1 IR2113SPBFC T-ND-1 TLV2464AIPW

BSS84CT-ND

HVCB1206T21

# 00MFICT-ND HMC1/8200MK R-ND CRCW 201030 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 A C PCB 2**  **Base plate assy**  **H A C PCB 2** 

**Base plate assy**  **-W ashing**  **H A C 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, Wa rning, Compressor H Sticker, Informational, Compressor 11

1

1

**1**

**1**

**H A C Motor**  **Stator Stack**



# Number **Qty**

**H A C Motor**  **Stator Plates - w/A**  **lignment Notch & Hol**  H AC Motor

Stator Plates - w/Notch & Holes Matl **H A C Motor**  **Stator Plates - w/A**  **lignment Notch**  H AC Motor

Stator Plates -

# w/Notch & No Holes Mate **H A C Motor**  **Stator Plates - No Notch**  H AC Motor

Stator Plates - No Notch Material **H A C Motor**  **Stator Plates - 3 notches - no**  **holes** H AC Motor

Stator Plates, 3 notches, no holes - ma **H A C 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 9

9

1

# 1

1

1

2

9

**1**

**1**

**1**



# Qty

**1**

**H A C Motor**  **Shaft H A**  **C Motor**

**Shaft, Machined**  H AC Motor

Shaft, Material **H A C Motor**  **Rotor A sm,**  **Riveted** H AC Motor

Rivets **H A C Motor** 

# We **ight #1 AC**  **Motor We**  **ight #1 Deburred**  **H A C Motor**  **We ight 1**  **Trimmed AC**  **Motor**

**We ight #1**  **Casting** AC Motor

We ight #1 Material **H A C Motor**  **Rotor Endplate #1**  **H A C Motor** 

**Rotor Endplate #1**  **Stamped** H AC Motor Rotor Endplate #1 Material **H A c Motor**  **Rotor A sm**  **H A C Motor** 

**Rotor Plate**



# Number

AC Motor Rotor Plate Material H AC Motor Magnets **H A C Motor**  **Rotor Endplate #2**  **H A C Motor** 

**Rotor Endplate #2**  **Stamped** H AC Motor Rotor Endplate #2 Material **H A C Motor**  **We ight #2** 

# H A **C Motor We**  **ight #2 Deburred**  **H A C Motor**  **We ight 2**  **Trimmed H A**  **C Motor**

**We ight #2**  **Casting** H AC Motor

We ight #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, A C**  **Pump Crank, As**  **m H Shaft, A**  **C**

**Pump Crank, Wa**  **shed H Shaft, A**  **C**

**Pump Crank, Machined** 

# H Shaft, AC Pump Crank, Material **H Shaft, A C**  **Pump Crank, Pin**  **H Shaft, A C** 

**Pump Crank, Pin, Deburred**  **H Shaft, A C**  **Pump Crank, Pin, Machined**  H Shaft, AC

Pump Crank, Pin, Material **H Balance, A C**  **Pump Crank, Wa**  **shed H Balance, A**  **C**

**Pump Crank H Balance, A**  **C**

**Pump Crank**  **Machined**



# Number

**H Balance, A C**  **Pump Crank** **Machined Stamped**  H Balance, AC

Pump Crank Material H Rubber Bushing, On Post **1**

H Gasket, AC Pump Material **1**

# H Pump

Transfer Guide Material 1

1

**1**

**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, Wa**  **shed 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, An**  **odize 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

**Al uminum -**  **380**

**Al uminum -** 

**380**

**1 Al**  **uminum -**

**380**

**1 Al**  **uminum -**

**380**

**1** Aluminum -

380

**1**

Page 1 of

# Material

**1 Al**  **uminum A3**  **80**

**1 Al**  **uminum**

**A3 80** 

**1 Al**  **uminum A3**  **80**

**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**

**6**

3

19

19

**1**

**1**

1

Page 6 of



# Qty

1

1

1

1

1

1

3

# 4

2

3

14

36

1 Commodity

Pricing

1 Commodity

Pricing

1 Commodity

Pricing **1**

**1 Al**  **uminum - 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

**Ny lon 6/6 (GF)** 

Page 9 of



# Material

1 PA66 GF30

**Ny lon 6/6 (GF)** 

**1** PA66

Nylon 6/6

Commodity Pricing

Commodity

# Pricing

Commodity Pricing

Commodity Pricing

Nylon 6/6

Commodity Pricing Nylon 6/6

**Ny lon 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 **Al uminum -**  **380**

# 1 Aluminum - 380

Commodity Pricing

Commodity Pricing

**1 Al**  **uminum 1**  **Al uminum** 

**1 Al**  **uminum**

**1 Al**  **uminum**

**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)

**Al uminum** 

**1 Al**  **uminum**

**1 Al**  **uminum**

**1 Al**  **uminum**

**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 Al**  **uminum**

**1 Al**  **uminum**

**1 Al**  **uminum**

**1 Al**  **uminum**

**1 Al**  **uminum**

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 A C Sy**  **stems**
**Level Sy**  **mbol Name Number**  **Qty**

**H Bracket A C Compressor**  **H Bracket A C**  

# 1

**Mount to Block Compressor**  **Mount to Block**  **0** H Bolt AC Compressor Bracket H Bolt AC **2** Compressor Bracket **0 H Electric A**  **C Compressor H Electric A**  **C 1**  **As sembly**  **Compressor As**  **sembly 1**  **H Housing, Coil, and H Housing,**  **1 Electronics A** 

**sm. Coil, and** 

**Electronics As**  **m. 2**  **H Housing A**

**sm., Potted H Housing**  **Electronics As**  **m., 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 A **C Sy stems** 
**Level Sy**  **mbol 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 TerminalPassthroughStamping **3 H Terminal Block,**  **H Terminal Passthrough A** 

**sm. Block,** 

**Passthrough As**  **m. 4**  **H Plate Terminal Block, H Plate**  **Passthrough A**

**sm Terminal** 

**Block, Passthrough**  **As m**  **5** H Plate Terminal Block, H Plate Passthrough Asm Terminal Block, Passthrough Asm-blank **4 H Leads Terminal Block,**  **H Leads Passthrough A** 

**sm Terminal** 

**Block, Passthrough**  **As m**  **3** H Bolt, Terminal Block H Bolt, Passthrough Terminal Block Passthrough **3 H Inductor A** 

**sm, Coil, Large H Inductor**  **As m, Coil,**  **Large 3**  **H Inductor A**

**sm, Coil, Small H Inductor**  **As m, Coil,**  **Small 3**  **H Capacitor, Large H Capacitor,**  **Large 3**  **H Terminal Block A sm.**  **H Terminal**

**Block A sm.** 

# 3 **H Terminal Interface H Terminal**  **As sembly**  **Interface As**  **sembly 3**  **H A C PCB 1 preassembled**  **H A C PCB 1**  **preassembled 4**  **H A C PCB 1 w all**  **H A C PCB 1 w**  **components all**  **components 5**  **H A C PCB 1 w Thru Hole**  **H A C PCB 1 w**  **mntd Thru Hole**  **mntd 6**  **H A C PCB 1 w SMT mntd** 

**1** H AC Board 1 Bare FR4 FR4 **2 H A**  **C 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 A**  **C board 1 TOP SIDE - SURFA CE 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 A**  **C PCB H Bracket A**  **C 1connector**  **PCB 1connector**  **4** H Bracket AC PCB H Bracket AC 1connector-Blank PCB1connectorBlank 3 H Screw IGBT to base H Screw IGBT to base

**3 H A**  **C PCB 2 preassembled H A**  **C PCB 2 preassembled**  **4 H A**  **C PCB 2 wo metal base H A**  **C PCB 2 wo metal base**  **5 H A**  **C PCB 2 w all H A**  **C PCB 2 w components**  **all components**  **6 H A**  **C PCB 2 w thru hole H A**  **C PCB 2 w mnted**  **thru hole mnted**  **7 H A**  **C PCB 2 w SMT mnted H A**  **C PCB 2 w SMT mnted**  **8 H A**  **C 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 A**  **C PCB 2 Base plate assy H A**  **C PCB 2 Base plate**  **assy 5**  **H A C PCB 2 Base plate**  **H A C PCB 2**  **assy -Washing**  **Base plate assy**  **-Washing 6**  **H A C PCB 2 Base plate**  **H A C PCB 2**  **assy -Machining**  **Base plate assy**  **** **Machining 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 A** 

**ssembly H Cover**  **As sembly**  **, 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 A **C Sy stems** 
**Level Sy**  **mbol Name Number** 

3 H Sticker, W arning, H Sticker, Compressor Wa rning, 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 A**  **sm. H Scroll**  **1**

**Impellar A**

**sm. 2**  **H A C Motor Magnets and**  **H A C Motor**  **Shaft A sm.**  **Magnets and Shaft A**  **sm. 3**  **H A C Motor Shaft**  **H A C Motor**  **Shaft 3**  **H A C Motor Magnets**  **H A C Motor**  **Magnets 3**  **H A c Motor Rotor A** 

**sm H A** 

**c Motor Rotor A**  **sm 4**  **H A C Motor Rotor Plate**  **H A C Motor**  **Rotor Plate 2**  **H Midplate A**

**sm. H Midplate** 

**As m.**  **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, A**  **C Pump H Bearing, A**  **C Pump**  

# Design Profit

®

# Copyright 2005© Munro & Associates, Inc.

# H A **C Sy stems** 
**Level Sy**  **mbol 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 A**  **C Pump, Crank A sm.**  **H A C Pump,** 

**Crank A sm.**  **3 H Shaft, A**  **C Pump Crank, H Shaft, A**  **C As**  **m Pump Crank,**  **As m**  **4 H Shaft, A**  **C Pump Crank, H Shaft, A**  **C Washed**  **Pump Crank, Washed**  **5 H Shaft, A**  **C Pump Crank, H Shaft, A**  **C Machined**  **Pump Crank, Machined**  **6** H Shaft, AC Pump Crank, H Shaft, AC Material Pump Crank, Material **4 H Shaft, A**  **C Pump Crank, Pin H Shaft, A**  **C Pump Crank,**  **Pin 5**  **H Shaft, A C Pump Crank,**  **H Shaft, A C**  **Pin, Deburred Pump Crank,**  **Pin, Deburred 6**  **H Shaft, A C Pump Crank,**  **H Shaft, A C**  **Pin, Machined Pump Crank,**  **Pin, Machined 7**  H Shaft, AC Pump Crank, Pin, H Shaft, AC Material Pump Crank, Pin, Material **3 H Balance, A**  **C Pump Crank, H Balance, A**  **C Washed**  **Pump Crank, Washed**  **4 H Balance, A**  **C Pump Crank - H Balance, A**  **C Deburred**  **Pump Crank 5**  **H Balance, A C Pump Crank -**  **H Balance, A C**  **Machined Pump** **Crank Machined** 



# Design Profit

®

# Copyright 2005© Munro & Associates, Inc.

# H A **C Sy stems** 
**Level Sy**  **mbol Name Number** 

**6 H Balance, A**  **C Pump Crank - H Balance, A**  **C Stamped**  **Pump Crank** **Machined Stamped**  **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, A**  **C Pump H Gasket, A**  **C 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 Al**  **uminum A3**  **80**

**1 Al**  **uminum A3**  **80**

**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 1 1 $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 1 8 $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

4

**1**

**1**

**1**

**1**

**1**

H AC Board 2 Bare FR4 1 $2.64 

# BOTTOM SMT RHM. 002AUTR-ND 6 $0.29 541-1. 0XTR-ND 3 $0.03 Capacitors 19 $0.01 Resistors 19 $0.01 **TOP SMT** PCE3155TR-ND 1 $0.32 PCE3155TR-ND 1 $0.32 PCE3155TR-ND 1 $0.32 IR2113SPBFC T-ND-1 1 $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 CRCW 201030 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 Al**  **uminum - 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 Al**  **uminum - 380** 

**1** Aluminum - 380

Commodity Pricing

Page

# Weight



# $0.00

**$0.13**

**$111.80**

**$100.48**

**$99.88**

**Al uminum**  **A3 80** 

Aluminum A380

1 of 14

# Piece Cost

# 1 3.41 1 1 $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 1 8 $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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### 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 COSTS MANUFACTURING RATES**  **Electrically Versus Mechanically Driven Air Conditioning Compressor**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America**  **North America**

**FOB Ship Point 47**  **450,000 1**  **450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Electrically Versus Mechanically Driven Air Conditioning Compressor**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America**  **North America**

**FOB Ship Point 47**  **450,000 1**  **450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Electrically Versus Mechanically Driven Air Conditioning Compressor**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**



### 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 Sub

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. 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: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error. T1 or OEM Mark-Up Rates:** 

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% **(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**
**Base Cost Impact to Vehicle: $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0**  **$0 Packaging Cost:**  **$0.00 Net Cost Impact to Vehicle:**  **$0.00 a) Items 1,2, & 3 must all equal same value otherwise**  **there is a computation error.** 



### 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 (W eeks/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** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America**  **North America**

**FOB Ship Point 47**  **450,000 1**  **450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Electrically Versus Mechanically Driven Air Conditioning Compressor**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Packaging Cost per**  **Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### 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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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**  **Project Process Requirement Process Information**  **Gross Mark-up Costs x Quantity 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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Projected Operating Pattern **Minimum Calculated Cycles Time**

**MANUFACTURING ASSUMPTIONS Manufacturing Costs x Quantity**  **Project Process Requirement Process Information**  **Gross Mark-up Costs x Quantity 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!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/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: R** **e f** **e r** **e n** **c e** **#** 

### 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** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Projected Operating Pattern **Minimum Calculated Cycles Time**

**MANUFACTURING ASSUMPTIONS Manufacturing Costs x Quantity**  **Project Process Requirement Process Information**  **Gross Mark-up Costs x Quantity 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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Days/ Week**  **Shifts./ Day**  **Hrs./ Shift**  **Hrs./ Wk**  **Wks./ Yr.**  **Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### Projected Operating Pattern **Minimum Calculated Cycles Time**

**MANUFACTURING ASSUMPTIONS Manufacturing Costs x Quantity**  **Project Process Requirement Process Information**  **Gross Mark-up Costs x Quantity 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