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 Subsystem

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 TECHNOLOG

2010 Ford Fusion, 3.0L V

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)

Item

Subsystem

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! $ - $ - $ - $ - $ - $ - $ -

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

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

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

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

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

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

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

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

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 TECHNOLOG

2010 Ford Fusion, 3.0L V

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)

Item

Subsystem

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)

SUBSYSTEM ROLL-UP #N/A #REF! #REF! #N/A #REF! #REF! #REF! #REF! #REF! #REF! #N/A $ - $ - $ - $ - $ - $ - $ -

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 TECHNOLOG

2010 Ford Fusion, 3.0L V

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)

Item

Subsystem

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 Cylinder Blocks

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

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

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

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

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

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

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

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

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

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

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

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

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

BASE TECHNOLOG

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 INFORMATION

Item

Subsystem

Sub-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: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 TECHNOLOG

2010 Ford Fusion, 3.0L V

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)

Item

Subsystem

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

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

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

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

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

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

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

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

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

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

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

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

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

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

SU

BS

YS

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

Material Labor Burden End Item 

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

05 Cylinder Blocks

A1 01 #N/A #REF! #REF! #N/A #REF! #REF! #REF! #REF! #REF! #REF! #N/A $ - $ - $ - $ - $ - $ - $ -

B1 02 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - $ - $ - $ - $ -

C1 03 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - $ - $ - $ - $ -

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

E1 65 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - $ - $ - $ - $ -

F1 66 #REF! #REF! #REF! $ -

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

INCREMENTAL COST TO U

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

TECHNO

LOGY 

PACKAG

INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Item

Subsystem

Sub-Subsystem

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

F1 66 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:5 of 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 TECHNOLOG

2010 Ford Fusion, 3.0L V

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)

Item

Subsystem

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)

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

H1 70 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - $ - $ - $ - $ -

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

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

K1 85 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - $ - $ - $ - $ - $ - $ -

L1 90 #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ - #REF! $ - $ - $ - $ - $ - $ - $ -

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

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

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

SU

BS

YS

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

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:6 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

140300 High Voltage Traction Battery Subsystem

1 00

2 01

3 02

4 03

5 04

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

End Item 

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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: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 DESCRIPTION

Item

Subsystem

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

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

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 DESCRIPTION

Item

Subsystem

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 Cylinder Blocks

A1 01

2

B1 02

2

C1 03

2

D1 04

2

E1 65

2

F1 66

2

BASE 

TECHNO

LOGY 

Item

Subsystem

Sub-Subsystem

End Item 

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

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

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

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

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

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

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

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

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

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

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

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

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

Tooling 

(x1000)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

BASE TECHNOLOGY PACKAGE COST INFORMATION

Investment

(X1000)

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: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 DESCRIPTION

Item

Subsystem

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

(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

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

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

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

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

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

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

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

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

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

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

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

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

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

2

SU

BS

YS

05 Cylinder Blocks

A1 01

B1 02

C1 03

D1 04

E1 65

F1 66

TECHNO

LOGY 

PACKAG

Item

Subsystem

Sub-Subsystem

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

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

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

End Item 

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

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

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

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

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

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

$ - $ -

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

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 DESCRIPTION

Item

Subsystem

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

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

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

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

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

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

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

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

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

N1 00

SU

BS

YS

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

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

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

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:11 of 15 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

140300 High Voltage Traction Battery Subsystem

1 00

2 01

3 02

4 03

5 04

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

$ -

$ -

$ -

$ -

$ -

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

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

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 DESCRIPTION

Item

Subsystem

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 DESCRIPTION

Item

Subsystem

Investment(X1

000)

05 Cylinder Blocks

A1 01

2

B1 02

2

C1 03

2

D1 04

2

E1 65

2

F1 66

2

BASE 

TECHNO

LOGY 

Item

Subsystem

Sub-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 DESCRIPTION

Item

Subsystem

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 Cylinder Blocks

A1 01

B1 02

C1 03

D1 04

E1 65

F1 66

TECHNO

LOGY 

PACKAG

Item

Subsystem

Sub-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 DESCRIPTION

Item

Subsystem

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

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

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

140300 High Voltage Traction Battery Subsystem

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! $ -

Subassembly

Component

Sub-Subsystem

Assembly

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)

Item

Subsystem

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ 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 Traction Battery Sensing & Control Modules #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! $ $ -

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&D

Subassembly

Component

Sub-Subsystem

Assembly

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)

Item

Subsystem

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ 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! $ -

H Battery Case Cooling Housing and Closeout Panels A.2 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 Wire 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&D

Subassembly

Component

Sub-Subsystem

Assembly

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)

Item

Subsystem

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ 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 Weld 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 Subsystem

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)

Subassembly

Component

Sub-Subsystem

Assembly

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)

Item

Subsystem

QTY/ 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

DRAFT

Subassembly

Component

Sub-Subsystem

Assembly

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)

Item

Subsystem

QTY/ 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

H Battery Case Cooling Housing and Closeout Panels A.2 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 Wire 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

DRAFT

Subassembly

Component

Sub-Subsystem

Assembly

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)

Item

Subsystem

QTY/ 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 Weld 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 Subsystem

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) Subassembly

Component

System 

ED&T/R&D

(x1000)

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

S

Assembly) ub-Subsystem

Part Number

Markup

Assembly

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) Subassembly

Component

System 

ED&T/R&D

(x1000)

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

S

Assembly) ub-Subsystem

Part Number

Markup

Assembly

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 Subsystem

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)

Subassembly

Component

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

QTY/ Subsystem

Notes

Sub-Subsystem

Part Number

Assembly

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)

Subassembly

Component

BASE TECHNOLOGY GENERAL PART INFORMATION:

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

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

QTY/ Subsystem

Notes

Sub-Subsystem

Part Number

Assembly

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 (Weeks/Year): OEM Plant Location:

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

Study Case#: 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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

1 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 In

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

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

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

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 (Weeks/Year): OEM Plant Location:

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

Study Case#: 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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

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

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 46 46A VO Transmission Assembly Oper 390 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 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 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 (Weeks/Year): OEM Plant Location:

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

Study Case#: 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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

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

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 57 57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 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 $0.00Assembly, 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, 72 72A VO Transmission Assembly Oper 600 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 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 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 (Weeks/Year): OEM Plant Location:

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

Study Case#: 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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

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

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 98 98A VO Transmission Assembly Oper 860 140300-N0502-01-18 1 Assembly OEM Transmission Assembly Not Applicable General Assembly-OEM 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 $0.00OEM, 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 (Weeks/Year): OEM Plant Location:

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

Study Case#: 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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

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

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 (Weeks/Year): OEM Plant Location:

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

Study Case#: 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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

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

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 (Weeks/Year): OEM Plant Location:

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

Study Case#: 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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

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

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

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

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

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 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 a

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 (Weeks/Year): OEM Plant Location:

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

Study Case#: 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 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Costs Broken Out In

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

Power-Split HEV Technology

MARK-UP COSTS Manufacturing Costs 

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.

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

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 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:

Reference #

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.33 $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 Wassher 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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 10 of 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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.56 $0.17 $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 46A VO Transmission Assembly Oper 390 140300-N0502-01-18 5 2 8 80 48 3840 117 30.72 85% 138 26.11 - 1 1 24 1.0 1.0

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.56 $0.17 $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

57A VO Transmission Assembly Oper Off-Line 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

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

72A VO Transmission Assembly Oper 600 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

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.56 $0.10 $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

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 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

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.00 $0.10 $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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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

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

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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! #DIV/0! 85% 0 #DIV/0! #DIV/0! - - - - 1.0 1.0

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

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

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.00

$0.28

$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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 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:

Reference #

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.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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

46A VO Transmission Assembly Oper 390 140300-N0502-01-18 150 24.00 1.00

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

150 24.00 1.00

150 24.00 -

150 24.00 -

150 24.00 1.00

150 24.00 1.00

57A VO Transmission Assembly Oper Off-Line 140300-N0502-01-18 150 24.00 1.00

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

72A VO Transmission Assembly Oper 600 140300-N0502-01-18 150 24.00 -

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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

98A VO Transmission Assembly Oper 860 140300-N0502-01-18 150 24.00 1.00

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

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

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 

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 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:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810ec171.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411