### Page:1 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

# 140300 High Voltage Traction Battery **Subsy stem** 
1 **00 Assembly of High Voltage Traction Battery Subsystem**  **#N/A #REF!**  **#REF! #N/A**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#N/A -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 2 **01 Traction Battery Assembly (Minus Electrical Modules)**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 3 **02 Traction Battery (Relays, Fuses, Disconnects, etc)**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 4 **03 Traction Battery Internal Wire Harnesses (Low & High Voltage)**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 5 **04 Traction Battery Sensing & Control Modules**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

# 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)** 

### 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 Total Markup**  **Cost (Component/**  **Assembly) Total** 

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

### System **ED&T/R&D (x1000)**  **Investment (X1000)**  

# 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 **05 Traction Battery Cooling Module**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 7 **70 Pipes, Hoses, Ducting**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 8 **75 Brackets, Housing, Covers**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 9 **80 Boltings**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 10 **81 Boltings - VO Assembly of Battery to Vehicle**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 11 **96 Brackets - Battery Interface to Body**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! -**  **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 12 **97 Vehicle Wiring - Body Harness**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! -**  **$ #REF!**  **- $**  **-**

**$ -** 

**$ -** 

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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:2 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

# 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)** 

### 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 Total Markup**  **Cost (Component/**  **Assembly) Total** 

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

### System **ED&T/R&D (x1000)**  **Investment (X1000)**  

# 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)

**#N/A #REF!**  **#REF! #N/A**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#N/A -**  **$ -** 

**$ -** 

**$** 

### -

**$ -** 

**$ -** 

**$ -** 

**$ 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:3 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

# 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)** 

### 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 Total Markup**  **Cost (Component/**  **Assembly) Total** 

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

### System **ED&T/R&D (x1000)**  **Investment (X1000)**  

# 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** 
A1 **01**
- $
-

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### -

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### -

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

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-

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### 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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**$ System**  **ED&T/R&D (x1000)**  **Tooling**

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY PACKAGE COST INFORMATION
Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly) Total Markup**  **Cost (Component/**  **Assembly) Total** 

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

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

# BASE **TECHNO LOGY**  Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** 

# BASE TECHNOLOGY PACKAGE COST INFORMATIONItemSubsystemSub-Subsystem



### G1 **67**
- $
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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: 8/23/2012 DRAFT

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

# 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)** 

### 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 Total Markup**  **Cost (Component/**  **Assembly) Total** 

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

### System **ED&T/R&D (x1000)**  **Investment (X1000)**  

# 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)

H1 **70**
- $
-

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**$ -** 

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

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

# 05 **Cy linder Blocks** 
A1 **01** #N/A #REF! #REF! **#N/A** #REF! #REF! #REF! #REF! **#REF!** #REF! **#N/A**
- $
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### B1 **02** #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**
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### C1 **03** #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**
- $
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### D1 **04** #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**
- $
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### E1 **65** #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**
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**(x1000) Investment** 

**(X1000)** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** 

# TECHNO **LOGY PACKAG**  **INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE**ItemSubsystemSub-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** 



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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:5 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

# 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)** 

### 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 Total Markup**  **Cost (Component/**  **Assembly) Total** 

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

### System **ED&T/R&D (x1000)**  **Investment (X1000)**  

# 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: 8/23/2012 DRAFT



# 140300 High Voltage Traction Battery **Subsy stem** 
1 **00** 2 **01** 3 **02** 4 **03** 5 **04** 

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**(X1000)** 

# 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**  

# 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** 



### 6 **05** 7 **70** 8 **75** 9 **80** 10 **81** 11 **96** 12 **97** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a -** 

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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: 8/23/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem


### End Item Scrap SG&A Profit ED&T-R&D Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D **System ED&T/R&D**  **(x1000) Tooling** 

**(x1000) System**  **ED&T/R&D (x1000)**  **Tooling**

**(x1000) Investment** 

**(X1000)** 

# 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**  

# 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**

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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:8 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem


### End Item Scrap SG&A Profit ED&T-R&D Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D **System ED&T/R&D**  **(x1000) Tooling** 

**(x1000) System**  **ED&T/R&D (x1000)**  **Tooling**

**(x1000) Investment** 

**(X1000)** 

# 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**  

# 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** 



# 05 **Cy linder Blocks** 
A1 **01** 2 B1 **02** 2 C1 **03** 2 D1 **04** 2 E1 **65** 2 F1 **66** 2 

# BASE **TECHNO LOGY** ItemSubsystemSub-Subsystem


### End Item

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**ED&T/R&D (x1000)**  

# BASE TECHNOLOGY PACKAGE COST INFORMATION

**Investment (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:9 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### H1 **70** 2 I1 **75** 2 J1 **80** 2 K1 **85** 2 L1 **90** 2 M1 **99** 2 N1 **00** End Item

Scrap SG&A Profit ED&T-R&D Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D **System ED&T/R&D**  **(x1000) Tooling** 

**(x1000) System**  **ED&T/R&D (x1000)**  **Tooling**

**(x1000) Investment** 

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# 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**  

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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### N1 **00** 2 **SU**

**BS YS** 



# 05 **Cy linder Blocks** 
A1 **01** B1 **02** C1 **03** D1 **04** E1 **65** F1 **66** 

# TECHNO **LOGY PACKAG** ItemSubsystemSub-Subsystem 

### -

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-

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

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

- $
-

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-

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-

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-

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**- $**  **- $**  

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

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

**ED&T/R&D (x1000)**  **Investment (X1000)**  **Tooling (x1000)** 



### F1 **66**
-

$
-

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-

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-

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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:10 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### G1 **67** H1 **70** I1 **75** J1 **80** K1 **85** L1 **90** M1 **99** End Item

Scrap SG&A Profit ED&T-R&D Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D **System ED&T/R&D**  **(x1000) Tooling** 

**(x1000) System**  **ED&T/R&D (x1000)**  **Tooling**

**(x1000) Investment** 

**(X1000)** 

# 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**  

# 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** 

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-

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### M1 **99** N1 **00**

**SU BS**  **YS** - $
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### #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF! -**  **$ -** 

**$ -** 

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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:11 of 15 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT



# 140300 High Voltage Traction Battery **Subsy stem** 
1 **00** 2 **01** 3 **02** 4 **03** 5 **04** 

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### -

**$**

**- $** 

**- $** 

**- $** 

**- $**  **Investment(X1 000)** 



### 6 **05** 7 **70** 8 **75** 9 **80** 10 **81** 11 **96** 12 **97** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a -** 

**$**

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### 0 **n/a -** 

**$**



### 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: 8/23/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem 

### 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: 8/23/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem 

### Investment(X1 **000)**



# 05 **Cy linder Blocks** 
A1 **01** 2 B1 **02** 2 C1 **03** 2 D1 **04** 2 E1 **65** 2 F1 **66** 2 

# BASE **TECHNO LOGY** ItemSubsystemSub-Subsystem



### G1 **67** 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: 8/23/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### H1 **70** 2 I1 **75** 2 J1 **80** 2 K1 **85** 2 L1 **90** 2 M1 **99** 2 N1 **00 Investment(X1** 

**000)**



### 2 **SU**

**BS YS** 



# 05 **Cy linder Blocks** 
A1 **01** B1 **02** C1 **03** D1 **04** E1 **65** F1 **66** 

# TECHNO **LOGY PACKAG** ItemSubsystemSub-Subsystem



### F1 **66**

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: 8/23/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### G1 **67** H1 **70** I1 **75** J1 **80** K1 **85** L1 **90** M1 **99 Investment(X1** 

**000)**



### 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 6 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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



### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

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### - $
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# 140300 High Voltage Traction Battery **Subsy stem** 
1 **00 Assembly of High Voltage Traction Battery Subsystem**  **#N/A #REF!**  **#REF! #N/A**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#N/A -**  **$** 

### A VO Battery Assembly (Assembly of modules into final battery pack) 14 03 00
- N0502
- 01 1 Full 1 

### #N/A 50.29 $ 44.30

$ **#N/A** 0.00 $ 0.03

$ 0.02

$
-

$ **0.06**

**$**
-

$ **#N/A -**  **$** 

### B VO Battery Pack Vehicle Installation 14 03 00
- N0502
- 02 1 Full 1 

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



### 2 **01 Traction Battery Assembly (Minus Electrical Modules)**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! -**  **$**SubassemblyComponentSub-SubsystemAssembly 

### Name/Description Part Number 

# 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 COST INFORMATIONQTY/Subsystem 

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

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM** 

### Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

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

2 **01 Traction Battery Assembly (Minus Electrical Modules)**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! -**  **$** 

### A H Battery Pack Module ( 8 D-cells/module) 14 03 01
- N0502
- 01 1 Full 1 

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

### A.1 H Battery, Single D-cell, NiMH 14 03 01
- N0502
- 02 208 Full 1 

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



### 3 **02 Traction Battery (Relays, Fuses, Disconnects, etc)**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! -**  **$** 

### A H Power Distribution Module 14 03 02
- N0502
- 01 1 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### A.1 H Power Distribution Module Asm 14 03 02
- N0502
- 02 1 Full 1 

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

### A.2 H Power Distribution Module Base Asm 14 03 02
- N0502
- 03 1 Full 1 

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

### A.3 H Resistor Harness Asm, PDM 14 03 02
- N0502
- 04 1 Full 1 

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

### A.4 H Charging & Relay Harness Assembly, PDM 14 03 02
- N0502
- 05 1 Full 1 

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

### A.5 H Relay Harness Assembly, PDM 14 03 02
- N0502
- 06 1 Full 1 

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

### A.6 H Case, PDM N5 14 03 02
- N0502
- 07 1 Full 1 

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

### A.7 H HV/LC Harness Asm 14 03 02
- N0502
- 08 1 Full 1 

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

### A.8 H HV/HC Harness Asm 14 03 02
- N0502
- 09 1 Full 1 

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



### 4 **03 Traction Battery Internal Wire Harnesses (Low & High Voltage)**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! -**  **$** 

### A H Harness Battery Pack - Asm 14 03 03
- N0502
- 01 1 Full 1 

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

### A.1 H Harness, Batt Pack Temp Sensing Harn Asm 14 03 03
- N0502
- 02 1 Full 1 

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

### A.2 H Harness, Batt Pack Voltage Sensing Harn Asm 14 03 03
- N0502
- 03 1 Full 1 

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

### B H Battery Bus Bar, Cell to Cell Bottom, Short, Asm 14 03 03
- N0502
- 04 1 Full 1 

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

### C H Bus Bar Cover/Cap Bottom Short Asm 14 03 03
- N0502
- 05 1 Full 1 

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

### D H Cable Battery Distribution Module Asm 14 03 03
- N0502
- 06 1 Full 1 

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

### E H Cable Battery to Service Plug Asm 14 03 03
- N0502
- 07 1 Full 1 

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

### F H Ground Strap Battery Pack to Body Assembly 14 03 03
- N0502
- 08 1 Full 1 

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



### 5 **04 Traction Battery Sensing & Control Modules**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! -**  **$** 

### Traction Battery Sensing & Control Modules **$** 

### A Battery Energy Control Module (BECM) - Black Connector 14 03 04
- N0502
- 01 1 Full 1 

### #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:2 of 6 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Name/Description Part Number 

# 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 COST INFORMATIONQTY/Subsystem 

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

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM** 

### Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

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

B Battery Pack Sensor Module (BPSM) - Grey Connector 14 03 04
- N0502
- 02 1 Full 1 

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



### 6 **05 Traction Battery Cooling Module**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! -**  **$** 

### A H Battery Cooling Subsystem 14 03 05
- N0502
- 01 1 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### A.1 H Battery Cooling Fan Subsystem T1 Assembly 14 03 05
- N0502
- 02 1 Full 1 

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

### A.2 H Battery Case Cooling Housing and Closeout Panels 14 03 05
- N0502
- 03 1 Full 1 

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

### A.3 H Battery Case Cooling Fan Assembly (minus electronics board) 14 03 05
- N0502
- 04 1 Full 1 

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

### A.4 H PCB - Batt. Cooling Fan Motor Ass'y 14 03 05
- N0502
- 05 1 Full 1 

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

### A.5 H Cooling Fan Power W ire Harn Asm 14 03 05
- N0502
- 06 1 Full 1 

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



### 7 **70 Pipes, Hoses, Ducting** 

8 **75 Brackets, Housing, Covers**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! -**  **$** 

### A H Cover Battery Pack Rear, Assembly (Cooling Fan Side) 14 03 75
- N0502
- 01 1 Full 1 

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

### B H Cover Battery Pack Front, Assembly (Control Module Side) 14 03 75
- N0502
- 02 1 Full 1 

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

### C H Cover Bracket Service Plug Ass'y O 14 03 75
- N0502
- 03 1 Full 1 

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

### D H Cover Battery Power Distribution Assembly 14 03 75
- N0502
- 04 1 Full 1 

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

### E H Bracket Battery to Vehicle Bracket R, ASM 14 03 75
- N0502
- 05 1 Full 1 

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

### F H Bracket Battery to Vehicle Bracket L, ASM 14 03 75
- N0502
- 06 1 Full 1 Price included in same cost sheet as "140375-N0502-05" 

### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### 9 **80 Boltings**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### A H Bolt, Battery End Cap to Inner Rod 14 03 80
- N0502
- 01 4 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### B H Bolt Battery Terminal Bottom 14 03 80
- N0502
- 02 52 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### C H Bolt, Cover to Inner Support 14 03 80
- N0502
- 03 16 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### D H Bolt Battery Pack End Cover 14 03 80
- N0502
- 04 8 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### E H Bolt Cover to inner support bar 14 03 80
- N0502
- 05 6 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### F H Nut Cover to Cover - Battery Pack 14 03 80
- N0502
- 06 6 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### G H Bolt Battery Pack End Cover 14 03 80
- N0502
- 07 10 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### H H Nut Power Distribution Module 14 03 80
- N0502
- 08 4 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### I H Nut Battery Pack Cable to Power Distribution Box 14 03 80
- N0502
- 09 2 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### J H Screw, Cover to Service Plug Connector 14 03 80
- N0502
- 10 2 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### K H Nut Service Plug Cover 14 03 80
- N0502
- 11 2 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### L H Nut Module Battery Management Control 14 03 80
- N0502
- 12 4 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### M H Nut Module Battery System Control 14 03 80
- N0502
- 13 4 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ PIA to VO Battery Assembly**  **(Assembly of modules into final battery pack)** 



### M H Nut Module Battery System Control 14 03 80
- N0502
- 13 4 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### N H Nut Cover Battery Power Distribution 14 03 80
- N0502
- 14 4 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



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

### Page:3 of 6 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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

### Name/Description Part Number 

# 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 COST INFORMATIONQTY/Subsystem 

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

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM** 

### Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

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

O H Bolt Cover Battery Power Distribution 14 03 80
- N0502
- 15 2 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### P H Bolt Cooling Fan 14 03 80
- N0502
- 16 6 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### Q H Nut Cooling Fan 14 03 80
- N0502
- 17 3 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### R H Bolt Battery Mnt Bracket 14 03 80
- N0502
- 18 4 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### S H Bolt Battery Mnt Bracket sml 14 03 80
- N0502
- 19 2 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### T H Bolt Battery Terminal Power Leads 14 03 80
- N0502
- 20 50 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### U H Bolt Battery Terminal Power 14 03 80
- N0502
- 21 1 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### V H Bolt Battery Terminal Power 14 03 80
- N0502
- 22 1 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### 10 **81 Boltings - VO Assembly of Battery to Vehicle**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### A H W eld Nut Battery Pack 14 03 81
- N0502
- 01 2 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### PIA to VO Battery Pack B H J-Nut Battery Pack Bracket 14 03 81
- N0502
- 02 8 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### C H Push Pin Bracket Retainer 14 03 81
- N0502
- 03 2 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### D H Bolt Bracket Battery Pack Bracket ( Bracket to Body) 14 03 81
- N0502
- 04 10 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### E H Bolt Battery Pack - Long ( Batt. to Bdy Mnt Brxt) 14 03 81
- N0502
- 05 4 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### F H Bolt Battery Pack - ( Batt. to Bdy Mnt Brxt) 14 03 81
- N0502
- 06 4 Full 1


### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### G H Bolt Battery Pack Ground Strap 14 03 81
- N0502
- 07 1 Full 1



### 11 **96 Brackets - Battery Interface to Body**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! -**  **$** 

### A H - Bracket Mount, Battery to Body (C-Pillar), LHS 14 03 96
- N0502
- 01 1 Full 1 

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

### B H - Bracket Mount, Battery to Body (C-Pillar), RHS 14 03 96
- N0502
- 02 1 Full 1 Price included in same cost sheet as "140396-N0502-01" 

### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### 12 **97 Vehicle Wiring - Body Harness**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! -**  **$ #REF!**  **- $**  

### A Body Harness (14A005) to BECM (50 pin) 14 03 97
- N0502
- 01 1 Full 1 Priced @ $0.50/circuit average. 

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

### B Body Harness (14A005) to Fan Control Module ( 4 Pin) 14 03 97
- N0502
- 02 1 Full 1 Price included in same cost sheet as "140397-N0502-01" 

### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### #N/A #REF! #REF! **#N/A** #REF! #REF! #REF! #REF! **#REF!** #REF! **#N/A -**  **$**



### 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**  **Vehicle Installation**

Complete Subsystem Quote

(Yes/No) 

## YES

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

### Page:4 of 6 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

0 **n/a n/a**  

# 140300 High Voltage Traction Battery **Subsy stem** 
1 **00 Assembly of High Voltage Traction Battery Subsystem**  A VO Battery Assembly (Assembly of modules into final battery pack) 14 03 00
- N0502
- 01 1 Full 1 

### B VO Battery Pack Vehicle Installation 14 03 00
- N0502
- 02 1 Full 1



### 2 **01 Traction Battery Assembly (Minus Electrical Modules)** SubassemblyComponentSub-SubsystemAssembly 

### Name/Description Part Number



# 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)** ItemSubsystemQTY/Subsystem 

### Notes 

# NEW TECHNOLOGY PACKAGE QUOTE

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

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$ Investment**  **(X1000) Tooling**  **(x1000)**



### 2 **01 Traction Battery Assembly (Minus Electrical Modules)**  A H Battery Pack Module ( 8 D-cells/module) 14 03 01
- N0502
- 01 1 Full 1 

### A.1 H Battery, Single D-cell, NiMH 14 03 01
- N0502
- 02 208 Full 1



### 3 **02 Traction Battery (Relays, Fuses, Disconnects, etc)** 

A H Power Distribution Module 14 03 02
- N0502
- 01 1 Full 1 

### A.1 H Power Distribution Module Asm 14 03 02
- N0502
- 02 1 Full 1 

### A.2 H Power Distribution Module Base Asm 14 03 02
- N0502
- 03 1 Full 1 

### A.3 H Resistor Harness Asm, PDM 14 03 02
- N0502
- 04 1 Full 1 

### A.4 H Charging & Relay Harness Assembly, PDM 14 03 02
- N0502
- 05 1 Full 1 

### A.5 H Relay Harness Assembly, PDM 14 03 02
- N0502
- 06 1 Full 1 

### A.6 H Case, PDM N5 14 03 02
- N0502
- 07 1 Full 1 

### A.7 H HV/LC Harness Asm 14 03 02
- N0502
- 08 1 Full 1 

### A.8 H HV/HC Harness Asm 14 03 02
- N0502
- 09 1 Full 1



### 4 **03 Traction Battery Internal Wire Harnesses (Low & High Voltage)** 

A H Harness Battery Pack - Asm 14 03 03
- N0502
- 01 1 Full 1 

### A.1 H Harness, Batt Pack Temp Sensing Harn Asm 14 03 03
- N0502
- 02 1 Full 1 

### A.2 H Harness, Batt Pack Voltage Sensing Harn Asm 14 03 03
- N0502
- 03 1 Full 1 

### B H Battery Bus Bar, Cell to Cell Bottom, Short, Asm 14 03 03
- N0502
- 04 1 Full 1 

### C H Bus Bar Cover/Cap Bottom Short Asm 14 03 03
- N0502
- 05 1 Full 1 

### D H Cable Battery Distribution Module Asm 14 03 03
- N0502
- 06 1 Full 1 

### E H Cable Battery to Service Plug Asm 14 03 03
- N0502
- 07 1 Full 1 

### F H Ground Strap Battery Pack to Body Assembly 14 03 03
- N0502
- 08 1 Full 1



### 5 **04 Traction Battery Sensing & Control Modules**  **- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$** 

### 5 **04 Traction Battery Sensing & Control Modules** 

A Battery Energy Control Module (BECM) - Black Connector 14 03 04
- N0502
- 01 1 Full 1 **- $**  **-**

**$**

**- $**  **-**

**$**



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

### Page:5 of 6 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTSubassemblyComponentSub-SubsystemAssembly 

### Name/Description Part Number 

# 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)** ItemSubsystemQTY/Subsystem 

### Notes 

# NEW TECHNOLOGY PACKAGE QUOTE

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

B Battery Pack Sensor Module (BPSM) - Grey Connector 14 03 04
- N0502
- 02 1 Full 1



### 6 **05 Traction Battery Cooling Module**  A H Battery Cooling Subsystem 14 03 05
- N0502
- 01 1 Full 1 

### A.1 H Battery Cooling Fan Subsystem T1 Assembly 14 03 05
- N0502
- 02 1 Full 1 

### A.2 H Battery Case Cooling Housing and Closeout Panels 14 03 05
- N0502
- 03 1 Full 1



### A.3 H Battery Case Cooling Fan Assembly (minus electronics board) 14 03 05
- N0502
- 04 1 Full 1 

### A.4 H PCB - Batt. Cooling Fan Motor Ass'y 14 03 05
- N0502
- 05 1 Full 1 

### A.5 H Cooling Fan Power W ire Harn Asm 14 03 05
- N0502
- 06 1 Full 1 **Investment (X1000)**  **Tooling (x1000)** 

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**



### 7 **70 Pipes, Hoses, Ducting** 

8 **75 Brackets, Housing, Covers** 

A H Cover Battery Pack Rear, Assembly (Cooling Fan Side) 14 03 75
- N0502
- 01 1 Full 1 

### B H Cover Battery Pack Front, Assembly (Control Module Side) 14 03 75
- N0502
- 02 1 Full 1 

### C H Cover Bracket Service Plug Ass'y O 14 03 75
- N0502
- 03 1 Full 1 

### D H Cover Battery Power Distribution Assembly 14 03 75
- N0502
- 04 1 Full 1 

### E H Bracket Battery to Vehicle Bracket R, ASM 14 03 75
- N0502
- 05 1 Full 1 

### F H Bracket Battery to Vehicle Bracket L, ASM 14 03 75
- N0502
- 06 1 Full 1 Price included in same cost sheet as "140375-N0502-05"


### 9 **80 Boltings** 

A H Bolt, Battery End Cap to Inner Rod 14 03 80
- N0502
- 01 4 Full 1 

### B H Bolt Battery Terminal Bottom 14 03 80
- N0502
- 02 52 Full 1 

### C H Bolt, Cover to Inner Support 14 03 80
- N0502
- 03 16 Full 1 

### D H Bolt Battery Pack End Cover 14 03 80
- N0502
- 04 8 Full 1 

### E H Bolt Cover to inner support bar 14 03 80
- N0502
- 05 6 Full 1 

### F H Nut Cover to Cover - Battery Pack 14 03 80
- N0502
- 06 6 Full 1 

### G H Bolt Battery Pack End Cover 14 03 80
- N0502
- 07 10 Full 1 

### H H Nut Power Distribution Module 14 03 80
- N0502
- 08 4 Full 1 

### I H Nut Battery Pack Cable to Power Distribution Box 14 03 80
- N0502
- 09 2 Full 1 

### J H Screw, Cover to Service Plug Connector 14 03 80
- N0502
- 10 2 Full 1 

### K H Nut Service Plug Cover 14 03 80
- N0502
- 11 2 Full 1 

### L H Nut Module Battery Management Control 14 03 80
- N0502
- 12 4 Full 1 

### M H Nut Module Battery System Control 14 03 80
- N0502
- 13 4 Full 1 **PIA to VO Battery Assembly (Assembly of modules into final**  **battery pack)** 

### - **$ -** 

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$** 

### M H Nut Module Battery System Control 14 03 80
- N0502
- 13 4 Full 1 

### N H Nut Cover Battery Power Distribution 14 03 80
- N0502
- 14 4 Full 1 **- $**  **-**

**$**

**- $**  **-**

**$**



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

### Page:6 of 6 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTSubassemblyComponentSub-SubsystemAssembly 

### Name/Description Part Number 

# 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)** ItemSubsystemQTY/Subsystem 

### Notes 

# NEW TECHNOLOGY PACKAGE QUOTE

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

O H Bolt Cover Battery Power Distribution 14 03 80
- N0502
- 15 2 Full 1 

### P H Bolt Cooling Fan 14 03 80
- N0502
- 16 6 Full 1 

### Q H Nut Cooling Fan 14 03 80
- N0502
- 17 3 Full 1 

### R H Bolt Battery Mnt Bracket 14 03 80
- N0502
- 18 4 Full 1 

### S H Bolt Battery Mnt Bracket sml 14 03 80
- N0502
- 19 2 Full 1 

### T H Bolt Battery Terminal Power Leads 14 03 80
- N0502
- 20 50 Full 1 

### U H Bolt Battery Terminal Power 14 03 80
- N0502
- 21 1 Full 1 

### V H Bolt Battery Terminal Power 14 03 80
- N0502
- 22 1 Full 1



### 10 **81 Boltings - VO Assembly of Battery to Vehicle**  A H W eld Nut Battery Pack 14 03 81
- N0502
- 01 2 Full 1 

### PIA to VO Battery Pack **Investment (X1000)**  **Tooling (x1000)** 

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$** 

### B H J-Nut Battery Pack Bracket 14 03 81
- N0502
- 02 8 Full 1 

### C H Push Pin Bracket Retainer 14 03 81
- N0502
- 03 2 Full 1 

### D H Bolt Bracket Battery Pack Bracket ( Bracket to Body) 14 03 81
- N0502
- 04 10 Full 1 

### E H Bolt Battery Pack - Long ( Batt. to Bdy Mnt Brxt) 14 03 81
- N0502
- 05 4 Full 1 

### F H Bolt Battery Pack - ( Batt. to Bdy Mnt Brxt) 14 03 81
- N0502
- 06 4 Full 1 

### G H Bolt Battery Pack Ground Strap 14 03 81
- N0502
- 07 1 Full 1



### 11 **96 Brackets - Battery Interface to Body** 

A H - Bracket Mount, Battery to Body (C-Pillar), LHS 14 03 96
- N0502
- 01 1 Full 1 

### B H - Bracket Mount, Battery to Body (C-Pillar), RHS 14 03 96
- N0502
- 02 1 Full 1 Price included in same cost sheet as "140396-N0502-01"



### 12 **97 Vehicle Wiring - Body Harness** 

A Body Harness (14A005) to BECM (50 pin) 14 03 97
- N0502
- 01 1 Full 1 Priced @ $0.50/circuit average. 

### B Body Harness (14A005) to Fan Control Module ( 4 Pin) 14 03 97
- N0502
- 02 1 Full 1 Price included in same cost sheet as "140397-N0502-01"



### 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**  **Vehicle Installation**

Complete Subsystem Quote

(Yes/No) 

## YES **- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**



### 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: 8/23/2012 DRAFT

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



### 0 **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

# 140300 High Voltage Traction Battery **Subsy stem** 
1 **00 Assembly of High Voltage Traction Battery Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 2 **01 Traction Battery Assembly (Minus Electrical Modules)**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 3 **02 Traction Battery (Relays, Fuses, Disconnects, etc)**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

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

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  **Total**

**Packaging 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 BASE TECHNOLOGY PACKAGE COST INFORMATION** QTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**Sub-Subsystem 

### Part Number MarkupAssembly 

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

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

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 4 **03 Traction Battery Internal Wire Harnesses (Low & High Voltage)**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 5 **04 Traction Battery Sensing & Control Modules**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 6 **05 Traction Battery Cooling Module**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 7 **70 Pipes, Hoses, Ducting**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 8 **75 Brackets, Housing, Covers**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 9 **80 Boltings**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 10 **81 Boltings - VO Assembly of Battery to Vehicle**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 11 **96 Brackets - Battery Interface to Body**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$** 

### 12 **97 Vehicle Wiring - Body Harness**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



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

### Page:2 of 4 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D **Net Component/**  **Assembly Cost Impact to**  **OEM** 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  **Total**

**Packaging 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 BASE TECHNOLOGY PACKAGE COST INFORMATION** QTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**Sub-Subsystem 

### Part Number MarkupAssembly 

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

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

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$**



### NOTES: 

## 1. Complete Subsystem Quote (Yes/No)
**= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of the competing technology** 

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

### Page:3 of 4 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

0 

# 140300 High Voltage Traction Battery **Subsy stem** 
1 **00 Assembly of High Voltage Traction Battery Subsystem** 

2 **01 Traction Battery Assembly (Minus Electrical Modules)** 
3 **02 Traction Battery (Relays, Fuses, Disconnects, etc)**  Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1)SubassemblyComponent 

# 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**QTY/Subsystem 

### NotesSub-Subsystem 

### Part NumberAssembly 

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

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

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$ Investment**  **(X1000) Tooling**  **(x1000)**



### 4 **03 Traction Battery Internal Wire Harnesses (Low & High Voltage)** 

5 **04 Traction Battery Sensing & Control Modules** 
6 **05 Traction Battery Cooling Module** 

7 **70 Pipes, Hoses, Ducting** 
8 **75 Brackets, Housing, Covers** 

9 **80 Boltings** 
10 **81 Boltings - VO Assembly of Battery to Vehicle** 

11 **96 Brackets - Battery Interface to Body** 

12 **97 Vehicle Wiring - Body Harness**  **- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**

**- $**  **-**

**$**



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

### Page:4 of 4 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1)SubassemblyComponent 

# 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**QTY/Subsystem 

### NotesSub-Subsystem 

### Part NumberAssembly 

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

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

**NOTES:** 

## 1. Complete Subsystem Quote (Yes/No)
**= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of the competing technology**  **Investment (X1000)**  **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 24 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 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#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM HV Battery Assembly** 

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

## Annual Component Volume: Shipping Method: **Component Description: VO Battery Assembly (Assembly of modules into final battery pack)**  

## Part Number: **140300-N0502-01** 

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

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

**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 VO Transmission Assembly Oper 5 140300-N0502-01-01 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00** 2 2A VO Transmission Assembly Oper 10 140300-N0502-01-02 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
3 3A VO Transmission Assembly Oper Off-Line 140300-N0502-01-03 **1** Washer OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00**
4 4A VO Transmission Assembly Oper 15 140300-N0502-01-04 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00**
5 5A VO Transmission Assembly Oper 20 140300-N0502-01-05 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$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 Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,375 10**  **North America North America**  **FOB Ship Point 48**  **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)**

6 6A VO Transmission Assembly Oper 30 140300-N0502-01-06 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.56**  **$0.33 $0.89**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.89 $0.89**  **$0.00**
7 7A VO Transmission Assembly Oper 40 140300-N0502-01-07 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.56**  **$0.33 $0.89**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.89 $0.89**  **$0.00**
8 8A VO Transmission Assembly Oper 50 140300-N0502-01-08 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
9 9A VO Transmission Assembly Oper 60 140300-N0502-01-09 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
10 10A VO Transmission Assembly Oper 70 140300-N0502-01-10 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.56**  **$0.10 $0.66**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.66 $0.66**  **$0.00**
11 11A VO Transmission Assembly Oper 80 140300-N0502-01-11 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
12 12A VO Transmission Assembly Oper 90 140300-N0502-01-12 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.56**  **$0.10 $0.66**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.66 $0.66**  **$0.00**
13 13A VO Transmission Assembly Oper 100 140300-N0502-01-13 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.56**  **$0.33 $0.89**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.89 $0.89**  **$0.00**
14 14A VO Transmission Assembly Oper 110 140300-N0502-01-14 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.56**  **$0.33 $0.89**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.89 $0.89**  **$0.00**
15 15A VO Transmission Assembly Oper 120 140300-N0502-01-15 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.56**  **$0.10 $0.66**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.66 $0.66**  **$0.00**
16 16A VO Transmission Assembly Oper 130 140300-N0502-01-16 **1** Functional Test OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
17 17A VO Transmission Assembly Oper 140 140300-N0502-01-17 **1** Functional Test OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
18 18A VO Transmission Assembly Oper 150 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
19 18A VO Transmission Assembly Oper 160 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
20 20A VO Transmission Assembly Oper 170 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00** 

### OEM, LMC 21 21A VO Transmission Assembly Oper 180 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
22 22A VO Transmission Assembly Oper 190 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
23 23A VO Transmission Assembly Oper 200 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
24 24A VO Transmission Assembly Oper 210 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
25 25A VO Transmission Assembly Oper 220 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$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 24 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 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#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM HV Battery Assembly** 

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

## Annual Component Volume: Shipping Method: **Component Description: VO Battery Assembly (Assembly of modules into final battery pack)**  

## Part Number: **140300-N0502-01** 

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

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

**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 Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,375 10**  **North America North America**  **FOB Ship Point 48**  **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)**

26 26A VO Transmission Assembly Oper 230 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
27 27A VO Transmission Assembly Oper 240 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
28 28A VO Transmission Assembly Oper 250 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
29 29A VO Transmission Assembly Oper 260 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
30 30A VO Transmission Assembly Oper 270 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
31 31A VO Transmission Assembly Oper 280 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.56**  **$0.33 $0.89**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.89 $0.89**  **$0.00** 

### Assembly, OEM, MC 32 32A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18 **1** Gage OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.56**  **$0.33 $0.89**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.89 $0.89**  **$0.00**
33 33A VO Transmission Assembly Oper OffiLine RTV 140300-N0502-01-18 **1** RTV OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.56**  **$0.33 $0.89**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.89 $0.89**  **$0.00**
34 34A VO Transmission Assembly Oper 290 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
35 35A VO Transmission Assembly Oper 300 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 2**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $1.11**  **$0.17 $1.28**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.28 $1.28**  **$0.00**
36 36A VO Transmission Assembly Oper 310 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00**
37 37A VO Transmission Assembly Oper 320 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
38 38A VO Transmission Assembly Oper 330 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
39 39A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18 **1** Gage OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, HC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$125.00 $125.00**  **$0.00 $0.00**  **$0.83 $0.83**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.83 $0.83**  **$0.00**
40 40 VO Transmission Assembly Oper 340 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
41 41A VO Transmission Assembly Oper 350 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
42 42A VO Transmission Assembly Oper 360 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
43 43A VO Transmission Assembly Oper 370 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
44 44A VO Transmission Assembly Oper 380 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
45 45A VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18 **1** Press OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.56**  **$0.33 $0.89**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.89 $0.89**  **$0.00**
46 46A VO Transmission Assembly Oper 390 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.56**  **$0.33 $0.89**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.89 $0.89**  **$0.00** 46 46A VO Transmission Assembly Oper 390 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.56**  **$0.33 $0.89**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.89 $0.89**  **$0.00**
47 47A VO Transmission Assembly Oper 400 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.56**  **$0.33 $0.89**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.89 $0.89**  **$0.00**
48 48A VO Transmission Assembly Oper 410 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
49 49A VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18 **1** Press OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.56**  **$0.33 $0.89**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.89 $0.89**  **$0.00**
50 50 VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18 **1** Press OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.56**  **$0.33 $0.89**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.89 $0.89**  **$0.00**
51 51A VO Transmission Assembly Oper 420 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$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: 3 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 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#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM HV Battery Assembly** 

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

## Annual Component Volume: Shipping Method: **Component Description: VO Battery Assembly (Assembly of modules into final battery pack)**  

## Part Number: **140300-N0502-01** 

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

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

**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 Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,375 10**  **North America North America**  **FOB Ship Point 48**  **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)**

52 52A VO Transmission Assembly Oper 430 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
53 53A VO Transmission Assembly Oper 440 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
54 54A VO Transmission Assembly Oper 450 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00**
55 55A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18 **1** Gage OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, HC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$125.00 $125.00**  **$0.00 $0.56**  **$0.83 $1.39**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.39 $1.39**  **$0.00**
56 56A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.56**  **$0.33 $0.89**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.89 $0.89**  **$0.00**
57 57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.56**  **$0.33 $0.89**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.89 $0.89**  **$0.00** 57 57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.56**  **$0.33 $0.89**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.89 $0.89**  **$0.00**
58 58A VO Transmission Assembly Oper 460 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
59 59A VO Transmission Assembly Oper 470 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 2**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $1.11**  **$0.17 $1.28**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.28 $1.28**  **$0.00**
60 60A VO Transmission Assembly Oper 480 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00**
61 61A VO Transmission Assembly Oper 490 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
62 62A VO Transmission Assembly Oper 500 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, HC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$125.00 $125.00**  **$0.00 $0.00**  **$0.83 $0.83**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.83 $0.83**  **$0.00**
63 63A VO Transmission Assembly Oper 510 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
64 64A VO Transmission Assembly Oper 520 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
65 65A VO Transmission Assembly Oper 530 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
66 66A VO Transmission Assembly Oper 540 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.56**  **$0.33 $0.89**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.89 $0.89**  **$0.00**
67 67A VO Transmission Assembly Oper 550 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
68 68A VO Transmission Assembly Oper 560 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 2**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $1.11**  **$0.17 $1.28**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.28 $1.28**  **$0.00**
69 69A VO Transmission Assembly Oper 570 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
70 70A VO Transmission Assembly Oper 580 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 2**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $1.11**  **$0.17 $1.28**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.28 $1.28**  **$0.00**
71 71A VO Transmission Assembly Oper 590 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 2**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $1.11**  **$0.17 $1.28**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.28 $1.28**  **$0.00**
72 72A VO Transmission Assembly Oper 600 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$125.00 $125.00**  **$0.00 $0.00**  **$0.83 $0.83**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.83 $0.83**  **$0.00** 72 72A VO Transmission Assembly Oper 600 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, HC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$125.00 $125.00**  **$0.00 $0.00**  **$0.83 $0.83**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.83 $0.83**  **$0.00**
73 73A VO Transmission Assembly Oper 610 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.56**  **$0.10 $0.66**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.66 $0.66**  **$0.00**
74 74A VO Transmission Assembly Oper 620 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.56**  **$0.10 $0.66**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.66 $0.66**  **$0.00**
75 75A VO Transmission Assembly Oper 630 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.56**  **$0.10 $0.66**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.66 $0.66**  **$0.00**
76 76A VO Transmission Assembly Oper 640 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.56**  **$0.10 $0.66**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.66 $0.66**  **$0.00**
77 77A VO Transmission Assembly Oper 650 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.56**  **$0.10 $0.66**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.66 $0.66**  **$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 24 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 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#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM HV Battery Assembly** 

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

## Annual Component Volume: Shipping Method: **Component Description: VO Battery Assembly (Assembly of modules into final battery pack)**  

## Part Number: **140300-N0502-01** 

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

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

**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 Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,375 10**  **North America North America**  **FOB Ship Point 48**  **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)**

78 78A VO Transmission Assembly Oper 660 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.56**  **$0.10 $0.66**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.66 $0.66**  **$0.00**
79 79A VO Transmission Assembly Oper 670 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.56**  **$0.10 $0.66**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.66 $0.66**  **$0.00**
80 80A VO Transmission Assembly Oper 680 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 4**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $2.22**  **$0.33 $2.55**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$2.55 $2.55**  **$0.00**
81 81A VO Transmission Assembly Oper 690 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
82 82A VO Transmission Assembly Oper 700 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
83 83A VO Transmission Assembly Oper 710 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00** 

### OEM, LMC 84 84A VO Transmission Assembly Oper 720 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
85 85A VO Transmission Assembly Oper 730 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
86 86A VO Transmission Assembly Oper 740 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
87 87A VO Transmission Assembly Oper 750 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
88 88A VO Transmission Assembly Oper 760 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
89 89A VO Transmission Assembly Oper 770 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
90 90A VO Transmission Assembly Oper 780 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
91 91A VO Transmission Assembly Oper 790 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
92 92A VO Transmission Assembly Oper 800 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
93 93A VO Transmission Assembly Oper 810 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 2**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $1.11**  **$0.17 $1.28**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.28 $1.28**  **$0.00**
94 94A VO Transmission Assembly Oper 820 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.00**  **$0.17 $0.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.17 $0.17**  **$0.00**
95 95A VO Transmission Assembly Oper 830 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MHC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$75.00 $75.00**  **$0.00 $0.00**  **$0.50 $0.50**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.50 $0.50**  **$0.00**
96 96A VO Transmission Assembly Oper 840 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
97 97A VO Transmission Assembly Oper 850 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
98 98A VO Transmission Assembly Oper 860 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00** 98 98A VO Transmission Assembly Oper 860 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
99 99A VO Transmission Assembly Oper 870 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.56**  **$0.10 $0.66**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.66 $0.66**  **$0.00**
100 100A VO Transmission Assembly Oper 880 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
101 101A VO Transmission Assembly Oper 890 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$0.00**
102 102A VO Transmission Assembly Oper 900 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
103 103A VO Transmission Assembly Oper 910 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LMC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$25.00 $25.00**  **$0.00 $0.56**  **$0.17 $0.72**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.72 $0.72**  **$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: 5 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 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#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM HV Battery Assembly** 

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

## Annual Component Volume: Shipping Method: **Component Description: VO Battery Assembly (Assembly of modules into final battery pack)**  

## Part Number: **140300-N0502-01** 

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

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

**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 Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,375 10**  **North America North America**  **FOB Ship Point 48**  **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)**

104 104A VO Transmission Assembly Oper 920 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
105 105A VO Transmission Assembly Oper 930 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00**
106 106A VO Transmission Assembly Test loop 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00**
107 107A VO Transmission Assembly Test 10 140300-N0502-01-18 **1** Test OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, HC **30 1**  **1 1**  0.000 **$0.00 $83.31**  **$125.00 $125.00**  **$0.00 $2.78**  **$4.17 $6.94**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$6.94 $6.94**  **$0.00**
108 108A VO Transmission Assembly Test 20 140300-N0502-01-18 **1** Test OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, HC **30 0**  **1 1**  0.000 **$0.00 $83.31**  **$125.00 $125.00**  **$0.00 $0.00**  **$4.17 $4.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$4.17 $4.17**  **$0.00**
109 109A VO Transmission Assembly Test 30 140300-N0502-01-18 **1** Test OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, HC **30 1**  **1 1**  0.000 **$0.00 $83.31**  **$125.00 $125.00**  **$0.00 $2.78**  **$4.17 $6.94**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$6.94 $6.94**  **$0.00** 

### OEM, HC 110 110A VO Transmission Assembly Test 40 140300-N0502-01-18 **1** Test OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, HC **30 0**  **1 1**  0.000 **$0.00 $83.31**  **$125.00 $125.00**  **$0.00 $0.00**  **$4.17 $4.17**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$4.17 $4.17**  **$0.00**
111 111A VO Transmission Assembly Test 50 140300-N0502-01-18 **1** Test OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, HC **30 1**  **1 1**  0.000 **$0.00 $83.31**  **$125.00 $125.00**  **$0.00 $2.78**  **$4.17 $6.94**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$6.94 $6.94**  **$0.00**
112 112A VO Transmission Assembly Oper 940 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
113 113A VO Transmission Assembly Oper 950 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
114 114A VO Transmission Assembly Oper 960 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
115 115A VO Transmission Assembly Oper 970 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
116 116A VO Transmission Assembly Oper 980 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 1**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.56**  **$0.10 $0.66**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.66 $0.66**  **$0.00**
117 117A VO Transmission Assembly Oper 990 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00**
118 118A VO Transmission Assembly Oper 1000 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, MC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$50.00 $50.00**  **$0.00 $0.00**  **$0.33 $0.33**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.33 $0.33**  **$0.00**
119 119A VO Transmission Assembly Oper 1010 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
120 120A VO Transmission Assembly Oper 1020 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
121 121A VO Transmission Assembly Oper 1030 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 2**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $1.11**  **$0.10 $1.21**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.21 $1.21**  **$0.00**
122 122A VO Transmission Assembly Oper 1040 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**
123 123A VO Transmission Assembly Oper 1050 140300-N0502-01-18 **1** Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 

### Transmission Assembly, OEM, LC **150 0**  **1 1**  0.000 **$0.00 $83.31**  **$15.00 $15.00**  **$0.00 $0.00**  **$0.10 $0.10**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.10 $0.10**  **$0.00**


### B 

## Purchase Part - High Impact Item (Full Cost Mapping)
1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 2 **0 #####**  **0 3**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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 2**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 5 **0 #####**  **0 1**  **1.1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 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**



### 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 24 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 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#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM HV Battery Assembly** 

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

## Annual Component Volume: Shipping Method: **Component Description: VO Battery Assembly (Assembly of modules into final battery pack)**  

## Part Number: **140300-N0502-01** 

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

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

**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 Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,375 10**  **North America North America**  **FOB Ship Point 48**  **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)**

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** 

### C 

## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)
1 1A H Battery Cable Clip **3** Mold T2/T3 Inject. Mold, SSLC PP-TD20 Mold/Cast/Sinter Operator Inject. Mold, SS **581 1**  **1 1**  0.017 **$0.99 $43.52**  **$16.39 $16.39**  **$0.02 $0.07**  **$0.03 $0.12**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.13 $0.40**  **$0.05** 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 Bus Bar Cover/Cap Bottom **1** Mold T2/T3 Inject. Mold, SSLC PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, SMS **581 1**  **1 1**  0.051 **$0.99 $43.52**  **$28.80 $28.80**  **$0.05 $0.07**  **$0.05 $0.18**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.19 $0.19**  **$0.05** 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**



### 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 24 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 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#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM HV Battery Assembly** 

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

## Annual Component Volume: Shipping Method: **Component Description: VO Battery Assembly (Assembly of modules into final battery pack)**  

## Part Number: **140300-N0502-01** 

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

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

**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 Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,375 10**  **North America North America**  **FOB Ship Point 48**  **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)**



### 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**
112 R H Bolt Battery Mnt Bracket **4** S **$0.00** $0.07 **$0.00 $0.28**  **$0.28** 113 S H Bolt Battery Mnt Bracket sml **2** S **$0.00** $0.02 **$0.00 $0.04**  **$0.04** 21 T H Bolt Battery Terminal Power Leads **50** S **$0.00** $0.05 **$0.00 $2.32**  **$2.32** 22 U H Bolt Battery Terminal Power **1** S **$0.00** $0.06 **$0.00 $0.06**  **$0.06** 23 V H Bolt Battery Terminal Power **1** S **$0.00** $0.06 **$0.00 $0.06**  **$0.06** 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 Material**  **$2.86**
**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$97.50 T1 or OEM Total Manufacturing Cost:**  **$2.86 $50.29**  **$44.30 $97.45**  **$0.00 $0.03**  **$0.02 $0.00**  **$0.06 $97.50** 

**T1 or OEM Mark-Up Rates:**
----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00% **(SAC) &T1 or OEM Mark-Up Values:**  **#N/A**
----- ----- ----- **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 Base Cost Impact to Vehicle:**  **#N/A $50.29**  **$44.30 #N/A**  **$0.00 $0.03**  **$0.02 $0.00**  **$0.06 #N/A**  **$0 $0**  **Packaging Cost: $0.00**  **Net Cost Impact to Vehicle: #N/A** 

**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 **57** 1000 **6 56250** 
**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 Returnable Last 5 Years Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. **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: 8 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 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#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM HV Battery Assembly** 

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

## Annual Component Volume: Shipping Method: **Component Description: VO Battery Assembly (Assembly of modules into final battery pack)**  

## Part Number: **140300-N0502-01** 

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

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

**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 Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,375 10**  **North America North America**  **FOB Ship Point 48**  **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)**



### "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: 9 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 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 VO Transmission Assembly Oper 5 140300-N0502-01-01 2A VO Transmission Assembly Oper 10 140300-N0502-01-02
3A VO Transmission Assembly Oper Off-Line 140300-N0502-01-03
4A VO Transmission Assembly Oper 15 140300-N0502-01-04
5A VO Transmission Assembly Oper 20 140300-N0502-01-05



### 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 **Tool, Fixture and Gauge 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** 

**$0.00 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper.5 Auto load case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper. 10 W assher automation **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper. Off-Line Part washer **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper. 15 Loaad case to assembly pallet **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper. 20 Auto clamp case to pallet and rotate **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  

### 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**

6A VO Transmission Assembly Oper 30 140300-N0502-01-06
7A VO Transmission Assembly Oper 40 140300-N0502-01-07
8A VO Transmission Assembly Oper 50 140300-N0502-01-08
9A VO Transmission Assembly Oper 60 140300-N0502-01-09
10A VO Transmission Assembly Oper 70 140300-N0502-01-10
11A VO Transmission Assembly Oper 80 140300-N0502-01-11
12A VO Transmission Assembly Oper 90 140300-N0502-01-12
13A VO Transmission Assembly Oper 100 140300-N0502-01-13
14A VO Transmission Assembly Oper 110 140300-N0502-01-14
15A VO Transmission Assembly Oper 120 140300-N0502-01-15
16A VO Transmission Assembly Oper 130 140300-N0502-01-16
17A VO Transmission Assembly Oper 140 140300-N0502-01-17
18A VO Transmission Assembly Oper 150 140300-N0502-01-18
18A VO Transmission Assembly Oper 160 140300-N0502-01-18
20A VO Transmission Assembly Oper 170 140300-N0502-01-18 **$0.56 $0.33**  **$0.89 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper. 30 Press in traction motor bearing and park lever seal **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.33**  **$0.89 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper. 40 Press dowels in case for cover and planetary housing, air assemble air inlet cover & r/d 1 bolt **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 50 nstall park lever comb & bullet assembly into case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 60 Align rooster comb shaft holes & install pin **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.10**  **$0.66 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  oper 70 Install 2 park lever springs and r/d spring bolt **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 80 Rotate housing **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.10**  **$0.66 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 90 Press to case 2 cover dowels & assemble 3 bearing shims to 3 beaing bores **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.33**  **$0.89 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 100 Load & press 2 tapered bearing races **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.33**  **$0.89 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 110 Load & press 1 tapered bearng race and 1 ball bearing race **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.10**  **$0.66 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 120 Install bullet receiver sleeve, half round bullet locator, position parking pawl arm, parking pawl pivot pin and spring **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 130 position bullet reciever and r/d 2 screws **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 140 Install oil pump assembly, r/d 3 bolts, install short passage tube **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 150 Install ling oil passage tube, mounting bracket, r/d 2 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 160 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 170 Repair bay entrance / exit **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0** 
21A VO Transmission Assembly Oper 180 140300-N0502-01-18
22A VO Transmission Assembly Oper 190 140300-N0502-01-18
23A VO Transmission Assembly Oper 200 140300-N0502-01-18
24A VO Transmission Assembly Oper 210 140300-N0502-01-18
25A VO Transmission Assembly Oper 220 140300-N0502-01-18 **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 180 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 190 Rotate case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 200 Install planetary assembly, oil pump drive and planet housing cover **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 210 Start, r/d 7 planetary housing cover bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 220 Position generator spped sensor wire harness thru case opening, attach wire to sensor, install speed senor - generator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0** 


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

26A VO Transmission Assembly Oper 230 140300-N0502-01-18
27A VO Transmission Assembly Oper 240 140300-N0502-01-18
28A VO Transmission Assembly Oper 250 140300-N0502-01-18
29A VO Transmission Assembly Oper 260 140300-N0502-01-18
30A VO Transmission Assembly Oper 270 140300-N0502-01-18
31A VO Transmission Assembly Oper 280 140300-N0502-01-18 

### 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 **Tool, Fixture and Gauge 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**  

### 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**

**$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 230 start & r/d 3 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 240 Position 2 generator & motor isolators thru case opening and start, r/d 2 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 250 position motor speed sensor wire harness thru case and attach to sensor **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 260 Install speed sensor (traction motor) and start, r/d 3 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 270 Install generator assembly, position speed sensor wire clip on bolt boss and start, r/d 3 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.33**  **$0.89 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 280 Install traction motor assembly, position speed sensor wire clip on bolt boss and start, r/d 3 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0** 
32A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18
33A VO Transmission Assembly Oper OffiLine RTV 140300-N0502-01-18
34A VO Transmission Assembly Oper 290 140300-N0502-01-18
35A VO Transmission Assembly Oper 300 140300-N0502-01-18
36A VO Transmission Assembly Oper 310 140300-N0502-01-18
37A VO Transmission Assembly Oper 320 140300-N0502-01-18
38A VO Transmission Assembly Oper 330 140300-N0502-01-18
39A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18
40 VO Transmission Assembly Oper 340 140300-N0502-01-18
41A VO Transmission Assembly Oper 350 140300-N0502-01-18
42A VO Transmission Assembly Oper 360 140300-N0502-01-18
43A VO Transmission Assembly Oper 370 140300-N0502-01-18
44A VO Transmission Assembly Oper 380 140300-N0502-01-18
45A VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18
46A VO Transmission Assembly Oper 390 140300-N0502-01-18 **$0.56 $0.33**  **$0.89 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper off-line gage cover rail to generator and motor bearings pockets / bearings and select shim and install in case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.33**  **$0.89 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper off-line RTV cover **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 290 pick and place cover over dowels to case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$1.11 $0.17**  **$1.28 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 300 Start and r/d to zero torquw 20 cover bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 310 Auto r/d 20 cover bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 320 Rotate case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 330 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.83**  **$0.83 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Off-line gage end play and torque to turn **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 340 Repair bay entrance / exit **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 350 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 360 Position traction speed sensor wire clip & r/d 1 bolts, position generator speed sensor wire clip & r/d 2 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 370 Install 6 terminal leads thru case and start, r/d 1 bolt per lead **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 380 Position motor and generator wires to terminal leads and start & r/d 1 bolts per wire **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.33**  **$0.89 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Off-Line Press inner roller bearings into both ends of generator transfer shaft, and outer ball bearing to cover side generator transfer shaft and tapered bearing to case side **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.33**  **$0.89 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 390 Align and press traction motor transfer shaft thru roller bearing in case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  46A VO Transmission Assembly Oper 390 140300-N0502-01-18
47A VO Transmission Assembly Oper 400 140300-N0502-01-18
48A VO Transmission Assembly Oper 410 140300-N0502-01-18
49A VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18
50 VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18
51A VO Transmission Assembly Oper 420 140300-N0502-01-18 **$0.56 $0.33**  **$0.89 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 390 Align and press traction motor transfer shaft thru roller bearing in case and OD spline into traction rotor shaft ID spline **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.33**  **$0.89 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 400 Press transfer shaft over generator planetary shaft **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 410 Align and assemble differential assembly into case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.33**  **$0.89 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Off-line press taper bearing on case side of output shaft, press outer gear set into transfer gear output shaft **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.33**  **$0.89 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Off-line press taper bearing on cover side of output shaft, start & r/d 1 nut on output shaft **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 420 Install output shaft assemmbly into case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  

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

### Page: 11 of 24 

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

52A VO Transmission Assembly Oper 430 140300-N0502-01-18
53A VO Transmission Assembly Oper 440 140300-N0502-01-18
54A VO Transmission Assembly Oper 450 140300-N0502-01-18
55A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18
56A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18
57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18 

### 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 **Tool, Fixture and Gauge 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**  

### 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**

**$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 430 Press roller bearing onto traction motor transfer shaft **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 440 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 450 Measure height from case rail to taper bearing race on differential, output dhaft and both transfer shafts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.83**  **$1.39 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper off-line, load bell housing, measure cover rail to above mentioned bearing pocket depths and select shims and install in cover and load / press 3 races into cover **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.33**  **$0.89 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Off-line install oil diffuser and start, r/d 3 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.33**  **$0.89 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Off-line RTV gear side of bell housing **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18
58A VO Transmission Assembly Oper 460 140300-N0502-01-18
59A VO Transmission Assembly Oper 470 140300-N0502-01-18
60A VO Transmission Assembly Oper 480 140300-N0502-01-18
61A VO Transmission Assembly Oper 490 140300-N0502-01-18
62A VO Transmission Assembly Oper 500 140300-N0502-01-18
63A VO Transmission Assembly Oper 510 140300-N0502-01-18
64A VO Transmission Assembly Oper 520 140300-N0502-01-18
65A VO Transmission Assembly Oper 530 140300-N0502-01-18
66A VO Transmission Assembly Oper 540 140300-N0502-01-18
67A VO Transmission Assembly Oper 550 140300-N0502-01-18
68A VO Transmission Assembly Oper 560 140300-N0502-01-18
69A VO Transmission Assembly Oper 570 140300-N0502-01-18
70A VO Transmission Assembly Oper 580 140300-N0502-01-18
71A VO Transmission Assembly Oper 590 140300-N0502-01-18
72A VO Transmission Assembly Oper 600 140300-N0502-01-18 **$0.56 $0.33**  **$0.89 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Off-line RTV gear side of bell housing **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 460 Auto place bell housing over dowels on case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$1.11 $0.17**  **$1.28 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 470 Start and r/d to zero torque 21 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 480 Auto r/d 21 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 490 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.83**  **$0.83 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 500 Torque to turn output shaft **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 510 Repair bay entrance / exit **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 520 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 530 rotate case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.33**  **$0.89 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 540 install seal in output shaft bores on both side of case and install input shaft seal to bell housing side **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 550 Rotate case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$1.11 $0.17**  **$1.28 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 560 Install oil cooler gasket, oil cooler cover and start, r/d 19 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 570 Install 2 dowels and electronic housing gasket **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$1.11 $0.17**  **$1.28 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 580 Position electronic housing over dowels 7 start 2 bolts, start, r/d to zero torque 10 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$1.11 $0.17**  **$1.28 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 590 Start and r/d to zero torque 20 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.83**  **$0.83 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 600 Auto r/d 32 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  72A VO Transmission Assembly Oper 600 140300-N0502-01-18
73A VO Transmission Assembly Oper 610 140300-N0502-01-18
74A VO Transmission Assembly Oper 620 140300-N0502-01-18
75A VO Transmission Assembly Oper 630 140300-N0502-01-18
76A VO Transmission Assembly Oper 640 140300-N0502-01-18
77A VO Transmission Assembly Oper 650 140300-N0502-01-18 **$0.00 $0.83**  **$0.83 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 600 Auto r/d 32 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.10**  **$0.66 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  oper 610 Install 2 current sensor bars over terminal leads, start & r/d 2 bolts into each current sensor **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.10**  **$0.66 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 620 Install traction motor control unit & r/d 6 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.10**  **$0.66 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 630 Install generator control unit & r/d 6 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.10**  **$0.66 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 640 Install Denso control unit & r/d 4 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.10**  **$0.66 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 650 Install 3 bus bars between traction control unit and current sensor bar & r/d 2 bolts each **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  

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

### Page: 12 of 24 

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

78A VO Transmission Assembly Oper 660 140300-N0502-01-18
79A VO Transmission Assembly Oper 670 140300-N0502-01-18
80A VO Transmission Assembly Oper 680 140300-N0502-01-18
81A VO Transmission Assembly Oper 690 140300-N0502-01-18
82A VO Transmission Assembly Oper 700 140300-N0502-01-18
83A VO Transmission Assembly Oper 710 140300-N0502-01-18 

### 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 **Tool, Fixture and Gauge 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**  

### 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**

**$0.56 $0.10**  **$0.66 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 660 Install 3 bus bars between generator control unit and sensor bar & r/d 2 bolts each **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.10**  **$0.66 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 670 Route all wires off control units before install cover then install wire harness into each control unit **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$2.22 $0.33**  **$2.55 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Off-line Main Control build up loop **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 690 Install main control start & r/d 6 bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 700 Fasten 3 wire clips and insert 4 wire connectors to circuit board **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 710 Install short bar, start, r/d nut / bolt **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0** 
84A VO Transmission Assembly Oper 720 140300-N0502-01-18
85A VO Transmission Assembly Oper 730 140300-N0502-01-18
86A VO Transmission Assembly Oper 740 140300-N0502-01-18
87A VO Transmission Assembly Oper 750 140300-N0502-01-18
88A VO Transmission Assembly Oper 760 140300-N0502-01-18
89A VO Transmission Assembly Oper 770 140300-N0502-01-18
90A VO Transmission Assembly Oper 780 140300-N0502-01-18
91A VO Transmission Assembly Oper 790 140300-N0502-01-18
92A VO Transmission Assembly Oper 800 140300-N0502-01-18
93A VO Transmission Assembly Oper 810 140300-N0502-01-18
94A VO Transmission Assembly Oper 820 140300-N0502-01-18
95A VO Transmission Assembly Oper 830 140300-N0502-01-18
96A VO Transmission Assembly Oper 840 140300-N0502-01-18
97A VO Transmission Assembly Oper 850 140300-N0502-01-18
98A VO Transmission Assembly Oper 860 140300-N0502-01-18 **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 720 install medium bar, start, r/d nut / bolt **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  oper 730 Install long bar, start, r/dnut /bolts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 740 Connect & r/d wires to lower black box **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 750 Install TACM connector to electronic housing, insert wire thru hole, start & r/d 3 bolts and terminate 2 wires to stud & r/d 2 nuts **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 760 Install 2 TACM #2 connectors and r/d 1 bolt each **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 770 Install large harness guide, start & r/d 4 screws **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 780 Install 5 harness clips to harness guide, r/d ground stud **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 790 Ppsition 3 wire harness with 7 connectors, terminate / plug in 9 connectors includes 2 existing connectors **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 800 Install cork gasket to electronic housing **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$1.11 $0.17**  **$1.28 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 810 Position cover & tab assembly, start & r/d to zero torque 2 studs **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.17**  **$0.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 820 Install & r/d to zero torque 18 bolts and 4 studs **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.50**  **$0.50 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 830 Auto r/d 22 fasteners **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 840 Rotate case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 850 Install shift lever indicator, lever, locking clamp, r/d 2 bolts, 1 stud **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 860 Install & r/d 2 studs w/ nuts, 2 coolant outlets and 1 temp sensor **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  98A VO Transmission Assembly Oper 860 140300-N0502-01-18
99A VO Transmission Assembly Oper 870 140300-N0502-01-18
100A VO Transmission Assembly Oper 880 140300-N0502-01-18
101A VO Transmission Assembly Oper 890 140300-N0502-01-18
102A VO Transmission Assembly Oper 900 140300-N0502-01-18
103A VO Transmission Assembly Oper 910 140300-N0502-01-18 **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 860 Install & r/d 2 studs w/ nuts, 2 coolant outlets and 1 temp sensor **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.10**  **$0.66 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 870 Rotate case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 880 Install & r/d small plug w/O-ring, 2 large plugs w/ O-ring and press in small coolant port **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 890 Feed & press vent tube and install rubber hose w/ clip **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 900 Rotate case **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.17**  **$0.72 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 910 Install & r/d 3 large studs, drain plug and cover plug **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0** 


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

### Page: 13 of 24 

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

104A VO Transmission Assembly Oper 920 140300-N0502-01-18
105A VO Transmission Assembly Oper 930 140300-N0502-01-18
106A VO Transmission Assembly Test loop 140300-N0502-01-18
107A VO Transmission Assembly Test 10 140300-N0502-01-18
108A VO Transmission Assembly Test 20 140300-N0502-01-18
109A VO Transmission Assembly Test 30 140300-N0502-01-18 

### 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 **Tool, Fixture and Gauge 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**  

### 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 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 920 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 930 Load test loop **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Test loop **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$2.78 $4.17**  **$6.94 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Test **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 120 **1.0 1.0**  **$0.00 $4.17**  **$4.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Test **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 120 **1.0 1.0**  **$2.78 $4.17**  **$6.94 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Test **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 120 **1.0 1.0** 
110A VO Transmission Assembly Test 40 140300-N0502-01-18
111A VO Transmission Assembly Test 50 140300-N0502-01-18
112A VO Transmission Assembly Oper 940 140300-N0502-01-18
113A VO Transmission Assembly Oper 950 140300-N0502-01-18
114A VO Transmission Assembly Oper 960 140300-N0502-01-18
115A VO Transmission Assembly Oper 970 140300-N0502-01-18
116A VO Transmission Assembly Oper 980 140300-N0502-01-18
117A VO Transmission Assembly Oper 990 140300-N0502-01-18
118A VO Transmission Assembly Oper 1000 140300-N0502-01-18
119A VO Transmission Assembly Oper 1010 140300-N0502-01-18
120A VO Transmission Assembly Oper 1020 140300-N0502-01-18
121A VO Transmission Assembly Oper 1030 140300-N0502-01-18
122A VO Transmission Assembly Oper 1040 140300-N0502-01-18
123A VO Transmission Assembly Oper 1050 140300-N0502-01-18 

## Purchase Part - High Impact Item (Full Cost Mapping) **$0.00 $4.17**  **$4.17 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Test **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 120 **1.0 1.0**  **$2.78 $4.17**  **$6.94 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper Test **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 120 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 940 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 950 Unload test loop **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 960 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 970 Auto oli fill **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.56 $0.10**  **$0.66 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 980 Install & r/d long plug **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 990 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.33**  **$0.33 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 1000 Case washer **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 1010 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 1020 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$1.11 $0.10**  **$1.21 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 1030 Unload to rack **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 1040 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  **$0.00 $0.10**  **$0.10 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Oper 1050 Powered accumulator **5 2**  **8 80**  **48 3840**  **117 30.72**  **85% 138**  **26.11**
- 1 1 24 **1.0 1.0**  

## Purchase Part - High Impact Item (Full Cost Mapping) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 3.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 2.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.1 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  

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

### Page: 14 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 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 **Tool, Fixture and Gauge 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**  

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



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)
1A H Battery Cable Clip
2A H Bus Bar Cover/Cap Bottom **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 

**$0.22 $0.08**  **$0.36 $0.00**  **$0.02 $0.01**  **$0.00 $0.04**  55-150 ton , 4 cavity mold **5 2**  **10 100**  **47 4700**  **281 12.80**  **85% 331**  **10.88** 6.20 1 4 24.80 **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.07 $0.05**  **$0.18 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  200-400 ton , 4 cavity mold **5 2**  **10 100**  **47 4700**  **94 38.40**  **85% 110**  **32.64** 6.20 1 4 24.80 **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0** 


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

### Page: 15 of 24 

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

R H Bolt Battery Mnt Bracket S H Bolt Battery Mnt Bracket sml T H Bolt Battery Terminal Power Leads U H Bolt Battery Terminal Power V H Bolt Battery Terminal Power 

### 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 **Tool, Fixture and Gauge 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**  

### 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 $0.28**  **$0.04 $2.32**  **$0.06 $0.06**  **$0.00 $0.00**  **$0.00 Labor**  **Burden TMC**  **Scrape SG&A**  **Profit ED&T**  **Mark-up Total**  **$50.29 $44.30**  **$97.45 $0.00**  **$0.03 $0.02**  **$0.00 $0.06**  **$97.50 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: 16 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 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 **Tool, Fixture and Gauge 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**  

### 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: 17 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 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 VO Transmission Assembly Oper 5 140300-N0502-01-01 2A VO Transmission Assembly Oper 10 140300-N0502-01-02
3A VO Transmission Assembly Oper Off-Line 140300-N0502-01-03
4A VO Transmission Assembly Oper 15 140300-N0502-01-04
5A VO Transmission Assembly Oper 20 140300-N0502-01-05



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

**150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- 6A VO Transmission Assembly Oper 30 140300-N0502-01-06
7A VO Transmission Assembly Oper 40 140300-N0502-01-07
8A VO Transmission Assembly Oper 50 140300-N0502-01-08
9A VO Transmission Assembly Oper 60 140300-N0502-01-09
10A VO Transmission Assembly Oper 70 140300-N0502-01-10
11A VO Transmission Assembly Oper 80 140300-N0502-01-11
12A VO Transmission Assembly Oper 90 140300-N0502-01-12
13A VO Transmission Assembly Oper 100 140300-N0502-01-13
14A VO Transmission Assembly Oper 110 140300-N0502-01-14
15A VO Transmission Assembly Oper 120 140300-N0502-01-15
16A VO Transmission Assembly Oper 130 140300-N0502-01-16
17A VO Transmission Assembly Oper 140 140300-N0502-01-17
18A VO Transmission Assembly Oper 150 140300-N0502-01-18
18A VO Transmission Assembly Oper 160 140300-N0502-01-18
20A VO Transmission Assembly Oper 170 140300-N0502-01-18 **150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00** 
- **150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00** 
- **150 24.00** 
- 21A VO Transmission Assembly Oper 180 140300-N0502-01-18
22A VO Transmission Assembly Oper 190 140300-N0502-01-18
23A VO Transmission Assembly Oper 200 140300-N0502-01-18
24A VO Transmission Assembly Oper 210 140300-N0502-01-18
25A VO Transmission Assembly Oper 220 140300-N0502-01-18 **150 24.00** 
- **150 24.00** 
- **150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00



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

### Page: 18 of 24 

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

26A VO Transmission Assembly Oper 230 140300-N0502-01-18
27A VO Transmission Assembly Oper 240 140300-N0502-01-18
28A VO Transmission Assembly Oper 250 140300-N0502-01-18
29A VO Transmission Assembly Oper 260 140300-N0502-01-18
30A VO Transmission Assembly Oper 270 140300-N0502-01-18
31A VO Transmission Assembly Oper 280 140300-N0502-01-18**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** 

**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
32A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18
33A VO Transmission Assembly Oper OffiLine RTV 140300-N0502-01-18
34A VO Transmission Assembly Oper 290 140300-N0502-01-18
35A VO Transmission Assembly Oper 300 140300-N0502-01-18
36A VO Transmission Assembly Oper 310 140300-N0502-01-18
37A VO Transmission Assembly Oper 320 140300-N0502-01-18
38A VO Transmission Assembly Oper 330 140300-N0502-01-18
39A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18
40 VO Transmission Assembly Oper 340 140300-N0502-01-18
41A VO Transmission Assembly Oper 350 140300-N0502-01-18
42A VO Transmission Assembly Oper 360 140300-N0502-01-18
43A VO Transmission Assembly Oper 370 140300-N0502-01-18
44A VO Transmission Assembly Oper 380 140300-N0502-01-18
45A VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18
46A VO Transmission Assembly Oper 390 140300-N0502-01-18 **150 24.00**  1.00
**150 24.00**  1.00
**150 24.00** 
- **150 24.00**  2.00
**150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00 46A VO Transmission Assembly Oper 390 140300-N0502-01-18
47A VO Transmission Assembly Oper 400 140300-N0502-01-18
48A VO Transmission Assembly Oper 410 140300-N0502-01-18
49A VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18
50 VO Transmission Assembly Oper Off-Line press 140300-N0502-01-18
51A VO Transmission Assembly Oper 420 140300-N0502-01-18 **150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00 

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

### Page: 19 of 24 

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

52A VO Transmission Assembly Oper 430 140300-N0502-01-18
53A VO Transmission Assembly Oper 440 140300-N0502-01-18
54A VO Transmission Assembly Oper 450 140300-N0502-01-18
55A VO Transmission Assembly Oper Off-Line gage 140300-N0502-01-18
56A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18
57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18**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** 

**150 24.00**  1.00
**150 24.00** 
- **150 24.00** 
-
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00 57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18
58A VO Transmission Assembly Oper 460 140300-N0502-01-18
59A VO Transmission Assembly Oper 470 140300-N0502-01-18
60A VO Transmission Assembly Oper 480 140300-N0502-01-18
61A VO Transmission Assembly Oper 490 140300-N0502-01-18
62A VO Transmission Assembly Oper 500 140300-N0502-01-18
63A VO Transmission Assembly Oper 510 140300-N0502-01-18
64A VO Transmission Assembly Oper 520 140300-N0502-01-18
65A VO Transmission Assembly Oper 530 140300-N0502-01-18
66A VO Transmission Assembly Oper 540 140300-N0502-01-18
67A VO Transmission Assembly Oper 550 140300-N0502-01-18
68A VO Transmission Assembly Oper 560 140300-N0502-01-18
69A VO Transmission Assembly Oper 570 140300-N0502-01-18
70A VO Transmission Assembly Oper 580 140300-N0502-01-18
71A VO Transmission Assembly Oper 590 140300-N0502-01-18
72A VO Transmission Assembly Oper 600 140300-N0502-01-18 **150 24.00**  1.00
**150 24.00** 
- **150 24.00**  2.00
**150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00**  1.00
**150 24.00** 
- **150 24.00**  2.00
**150 24.00**  1.00
**150 24.00**  2.00
**150 24.00**  2.00
**150 24.00** 
- 72A VO Transmission Assembly Oper 600 140300-N0502-01-18
73A VO Transmission Assembly Oper 610 140300-N0502-01-18
74A VO Transmission Assembly Oper 620 140300-N0502-01-18
75A VO Transmission Assembly Oper 630 140300-N0502-01-18
76A VO Transmission Assembly Oper 640 140300-N0502-01-18
77A VO Transmission Assembly Oper 650 140300-N0502-01-18 **150 24.00** 
- **150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00 

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

### Page: 20 of 24 

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

78A VO Transmission Assembly Oper 660 140300-N0502-01-18
79A VO Transmission Assembly Oper 670 140300-N0502-01-18
80A VO Transmission Assembly Oper 680 140300-N0502-01-18
81A VO Transmission Assembly Oper 690 140300-N0502-01-18
82A VO Transmission Assembly Oper 700 140300-N0502-01-18
83A VO Transmission Assembly Oper 710 140300-N0502-01-18**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** 

**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  4.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
84A VO Transmission Assembly Oper 720 140300-N0502-01-18
85A VO Transmission Assembly Oper 730 140300-N0502-01-18
86A VO Transmission Assembly Oper 740 140300-N0502-01-18
87A VO Transmission Assembly Oper 750 140300-N0502-01-18
88A VO Transmission Assembly Oper 760 140300-N0502-01-18
89A VO Transmission Assembly Oper 770 140300-N0502-01-18
90A VO Transmission Assembly Oper 780 140300-N0502-01-18
91A VO Transmission Assembly Oper 790 140300-N0502-01-18
92A VO Transmission Assembly Oper 800 140300-N0502-01-18
93A VO Transmission Assembly Oper 810 140300-N0502-01-18
94A VO Transmission Assembly Oper 820 140300-N0502-01-18
95A VO Transmission Assembly Oper 830 140300-N0502-01-18
96A VO Transmission Assembly Oper 840 140300-N0502-01-18
97A VO Transmission Assembly Oper 850 140300-N0502-01-18
98A VO Transmission Assembly Oper 860 140300-N0502-01-18 **150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  2.00
**150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00**  1.00
**150 24.00**  1.00 98A VO Transmission Assembly Oper 860 140300-N0502-01-18
99A VO Transmission Assembly Oper 870 140300-N0502-01-18
100A VO Transmission Assembly Oper 880 140300-N0502-01-18
101A VO Transmission Assembly Oper 890 140300-N0502-01-18
102A VO Transmission Assembly Oper 900 140300-N0502-01-18
103A VO Transmission Assembly Oper 910 140300-N0502-01-18 **150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00**  1.00
**150 24.00** 
- **150 24.00**  1.00


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### Page: 21 of 24 

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

104A VO Transmission Assembly Oper 920 140300-N0502-01-18
105A VO Transmission Assembly Oper 930 140300-N0502-01-18
106A VO Transmission Assembly Test loop 140300-N0502-01-18
107A VO Transmission Assembly Test 10 140300-N0502-01-18
108A VO Transmission Assembly Test 20 140300-N0502-01-18
109A VO Transmission Assembly Test 30 140300-N0502-01-18**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** 

**150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **30 120.00**  1.00
**30 120.00** 
- **30 120.00**  1.00
110A VO Transmission Assembly Test 40 140300-N0502-01-18
111A VO Transmission Assembly Test 50 140300-N0502-01-18
112A VO Transmission Assembly Oper 940 140300-N0502-01-18
113A VO Transmission Assembly Oper 950 140300-N0502-01-18
114A VO Transmission Assembly Oper 960 140300-N0502-01-18
115A VO Transmission Assembly Oper 970 140300-N0502-01-18
116A VO Transmission Assembly Oper 980 140300-N0502-01-18
117A VO Transmission Assembly Oper 990 140300-N0502-01-18
118A VO Transmission Assembly Oper 1000 140300-N0502-01-18
119A VO Transmission Assembly Oper 1010 140300-N0502-01-18
120A VO Transmission Assembly Oper 1020 140300-N0502-01-18
121A VO Transmission Assembly Oper 1030 140300-N0502-01-18
122A VO Transmission Assembly Oper 1040 140300-N0502-01-18
123A VO Transmission Assembly Oper 1050 140300-N0502-01-18 

## Purchase Part - High Impact Item (Full Cost Mapping) **30 120.00** 
- **30 120.00**  1.00
**150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00**  1.00
**150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00** 
- **150 24.00**  2.00
**150 24.00** 
- **150 24.00** 
- 

## Purchase Part - High Impact Item (Full Cost Mapping)
**#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- 

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

### Page: 22 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 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.**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** 

**#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
-



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)
1A H Battery Cable Clip
2A H Bus Bar Cover/Cap Bottom **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
-

**581 6.20**  1.00 **#DIV/0! #DIV/0!** 
- **581 6.20**  1.00 **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
- **#DIV/0! #DIV/0!** 
-


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

### Page: 23 of 24 

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

R H Bolt Battery Mnt Bracket S H Bolt Battery Mnt Bracket sml T H Bolt Battery Terminal Power Leads U H Bolt Battery Terminal Power V H Bolt Battery Terminal Power**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** 



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

### Page: 24 of 24 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 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.**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** 



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