### Page:1 of 3 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/13/2012
DRAFT

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



### USD **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD** 

# 03 **Body Sy**  **stem C**

3 **08 Exterior Trim & Ornamentation Subsystem** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 4 **Radiator Grill 3.47**  **0.05 0.21**  **3.74 0.03**  **0.41 0.33**  **0.07 0.83** 

**- 4.57** 

**- -**  **- 3.63**  **0.06**



### 5 **Lower Exterior Finishers 10.96**  **0.53 1.05**  **12.54 0.09**  **1.39 1.10**  **0.22 2.80** 

**- 15.33** 

**- -**  **- 11.43**  **0.61**



### 6 **Upper Exterior & Roof Finish 1.82**  **0.07 0.33**  **2.22 0.02**  **0.19 0.25**  **0.04 0.50** 

**- 2.72** 

**- -**  **- 2.02**  **0.08**



### 7 **Rear Closure Finishers 3.29**  **0.04 0.39**  **3.72 0.03**  **0.41 0.33**  **0.07 0.83** 

**- 4.55** 

**- -**  **- 3.44**  **0.05**



# SYSTEM & SUBSYSTEM DESCRIPTION

Manufacturing 

# NEW TECHNOLOGY GENERAL PART INFORMATION

Manufacturing **Total Manufacturing** 
**Cost (Component/**  **Assembly) Tooling**  **(x1000)**ItemSubsystem Markup **Net Component/**  **Assembly Cost Impact to OEM**  **Total Markup**
**Cost (Component/**  **Assembly) Total** 

**Packaging**
**Cost (Component/**  **Assembly) System** 
**ED&T/R&D (x1000)**  

### Sub-Subsystem Description **Investment (X1000)**  

# Technology **Level:** Toyota Venza Mass

- Reduction and Cost Analysis **Vehicle Class:** Small & Mid Size Cross

- Over Passenger Vehicle **Study Case#:** 07

- 069

- 303LW

8 **Rear Spoiler Assembly 4.37**  **0.10 0.71**  **5.18 0.04**  **0.57 0.45**  **0.09 1.15** 

**- 6.33** 

**- -**  **- 4.56**  **0.12**



### 9 **Grill - Cowl Vent 2.07**  **0.14 0.96**  **3.17 0.02**  **0.35 0.28**  **0.06 0.71** 

**- 3.88** 

**- -**  **- 2.12**  **0.16**



### 10 **09 Rear View Mirrors Subsystem** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 11 **Exterior Mirror - Driver Side 2.25**  **0.25 0.19**  **2.69 0.02**  **0.30 0.24**  **0.05 0.60** 

**- 3.30** 

**- -**  **- 2.54**  **0.26**



### 12 **Exterior Mirror - Passenger Side 2.25**  **0.25 0.19**  **2.69 0.02**  **0.30 0.24**  **0.05 0.60** 

**- 3.30** 

**- -**  **- 2.54**  **0.26**



### 13 **23 Front End Module** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 14 **Module - Front Bumper & Fascia 10.49**  **0.29 2.10**  **12.88 0.09**  **1.42 1.13**  **0.23 2.87** 

**- 15.75** 

**- -**  **- 12.04**  **0.32**



### 15 **24 Rear End Module Subsystem** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -** 



### 16 **Module - Rear Bumper and Fascia 11.10**  **0.31 2.11**  **13.52 0.09**  **1.50 1.19**  **0.24 3.02** 

**- 16.54** 

**- -**  **- 12.72**  **0.35**



### 52.07 **2.04 8.24**  **62.35 0.44**  **6.84 5.52**  **1.11 13.90** 

**- 76.25** 

**- -**  **-** 

### 57.02 **2.27 SUBSYSTEM ROLL-UP** 

09000064810d3b0c.xls
EPA Contract:EP-C-07-069 W A1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:2 of 3 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/13/2012
DRAFT



# 03 **Body Sy**  **stem C**

3 **08**

4

5

6

7ItemSubsystem

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



### USD **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD**  **USD USD** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**

**0.24 3.93**  **0.03 0.41**  **0.33 0.07**  **0.83**

**- 4.76** 

**- -**  **- 0.16**  **0.01 0.03**  **0.20**

**- -**  **- -**  **- -**  **0.20**

**1.19 13.22**  **0.02 1.46**  **1.16 0.23**  **2.87**

**- 16.09** 

**- -**  **- 0.47**  **0.07 0.14**  **0.68 (0.07)**  **0.08 0.06**  **0.01 0.08** 

**- 0.76** 

**0.38 2.48**  **0.02 0.27**  **0.22 0.04**  **0.55**

**- 3.03** 

**- -**  **- 0.20**  **0.01 0.05**  **0.26 0.00**  **0.08 (0.03)**  **0.00 0.06** 

**- 0.32** 

**0.43 3.92**  **0.03 0.43**  **0.34 0.07**  **0.87**

**- 4.79** 

**- -**  **- 0.15**  **0.01 0.05**  **0.20 0.00**  **0.02 0.02**  **0.00 0.04** 

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

**(x1000) Investment** 

**(X1000) Total**  **Manufacturing**
**Cost (Component/**  **Assembly)** Markup **Total Markup**
**Cost (Component/**  **Assembly) Total**  **Packaging**
**Cost (Component/**  **Assembly) Net** 

**Component/ Assembly Cost**  **Impact to OEM Total**  **Packaging**
**Cost (Component/**  **Assembly) Net** 

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

# BASE TECHNOLOGY GENERAL PART INFORMATION **INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE**

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



### 8

9

10 **09**

11

12

13 **23**

14

15 **24**

16 **0.84 5.52**  **0.04 0.61**  **0.48 0.10**  **1.23**

**- 6.75** 

**- -**  **- 0.19**  **0.02 0.13**  **0.34 0.00**  **0.04 0.03**  **0.01 0.08** 

**- 0.42** 

**1.13 3.40**  **0.02 0.38**  **0.30 0.06**  **0.76**

**- 4.16** 

**- -**  **- 0.04**  **0.02 0.17**  **0.23 0.00**  **0.03 0.02**  **0.00 0.05** 

**- 0.28** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**

**0.20 3.00**  **0.02 0.33**  **0.26 0.05**  **0.67**

**- 3.67** 

**- -**  **- 0.28**  **0.01 0.01**  **0.30 0.00**  **0.03 0.03**  **0.01 0.07** 

**- 0.37** 

**0.20 3.00**  **0.02 0.33**  **0.26 0.05**  **0.67**

**- 3.67** 

**- -**  **- 0.28**  **0.01 0.01**  **0.30 0.00**  **0.03 0.03**  **0.01 0.07** 

**- 0.37** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**

**2.35 14.71**  **0.10 1.63**  **1.29 0.26**  **3.28**

**- 17.99** 

**- -**  **- 1.55**  **0.03 0.24**  **1.83 0.01**  **0.20 0.16**  **0.03 0.41** 

**- 2.24** 

**- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **- -**  **-**

**2.35 15.42**  **0.11 1.71**  **1.35 0.27**  **3.44**

**- 18.86** 

**- -**  **- 1.62**  **0.04 0.24**  **1.90 0.01**  **0.21 0.17**  **0.03 0.42** 

**- 2.32** 



### 9.30 **68.59 0.40**  **7.56 6.00**  **1.21 15.18** 

**- 83.77** 

**- -**  **-** 

### 4.95 **0.23 1.06**  **6.24 (0.03)**  **0.72 0.48**  **0.11 1.27** 

**- 7.52** 

09000064810d3b0c.xls
EPA Contract:EP-C-07-069 W A1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:3 of 3 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study**
**EP-C-07-069 WA1-3** Printed: 8/13/2012
DRAFT



# 03 **Body Sy**  **stem C**

3 **08**

4

5

6

7ItemSubsystem



### USD **USD USD** 

**- -**  **-**

**- -**  **-**

**- -**  **-**

**- -**  **-**

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

**(x1000) Investment** 

**(X1000)** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

8

9

10 **09**

11

12

13 **23**

14

15 **24**

16 **- -**  **-**

**- -**  **-**

**- -**  **-**

**- -**  **-**

**- -**  **-**

**- -**  **-**

**- -**  **-**

**- -**  **-**

**- -**  **-**

**- -**  **-**



### 09000064810d3b0c.xls
EPA Contract:EP-C-07-069 W A1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

# Top Level **Second Tier Third Tier** 

**0 Misc.**  Velcro Brand Hook-and-Loop Strips Zipper Toggle
We dge Anchor
Stitches
Buckle
Button
**1 Threaded Fastener** 
Screws
Screw Anchor Captive Threaded Fasteners
Nut
Stud
Threaded Insert
Threaded Rod
T-Fasteners
**2 Washer** 
Flat Lock/Split
Thrust
Bevel Cup Spring
Serrated/Star
Curve Disc
**3 Rivet** 
**4 Clamp** 
Hose
Pinch
Wo rm Screw Toggle
**5 Clip**  R-clip Circlip

**6 Nail**  Staple
Tack
**7 Pin** 
Clevis Pin
Cotter Pin
Dowel Pin Linchpin Spring Pin Peg
Stud
**8 Ring**  Retaining Ring 

# 70 - Fasteners

# E-Ring

**9 Strap** 
Tie

**Top Level Second Tier**  **Third Tier**
**0 Misc.**  Loctite (non-adhesive)

**Seals/Gaskets**
**1 Liquid/Paste** 
RTV
**2 Flat** 

**3 Extruded/Molded**  O-Rings
Grommet
**Ad hesives** 
**4 Liquid/Paste** 
Loctite
**5 Tape/Sheet** 
Roll
Adhesive Band
**6 Reactive (Chemical)** 

**7 Thermo**  Shrinkwrap Shrinktubing

**Top Level Second Tier**  **Third Tier**
**0 Misc.** 

**Bearings**
**1 Rolling Element** 
Radial
Radial Ball Angular Contact Cy lindrical
Needle Spherical Taper
**2 Fluid** 
Oil
Air
Journal
**3 Ma**  **gnetic**

**4 Flexure** 



# 80 - Seals/Gaskets/A **dhesives**

**90 - Bearings/Wheels/Pulley /Sprocket** 

# 5 **Bushing**

**6 Wheels** 

**7 Pulleys** 

**8 Sprockets** 

All other commodity

item s that do not belong in previous categories 

# 99 - Miscellaneous

# Vehicle Cells Price 25,063.00 $ Retail Price Equivalent 1.5
Estimated Cost to Manufacture Venza 16,708.67 $

10% Vehicle Manufacturing Cost Increase 1,670.87 $ 17.5% Vehicle Manufacturing Cost Increase 2,924.02 $ 25% Vehicle Manufacturing Cost Increase 4,177.17 $

We ight of Venza Vehicle "kg" 1710.5 20% Mass-reduction "kg" 342.10

**Level #1A**

Average Cost/Kilogram @ 0-5% Mass Reduction **≤$0.00**

**Level #1B** Average Cost/Kilogram @ 5-10% Mass Reduction **>$0.00 to ≤ $1.00** 

**Level #1C** Average Cost/Kilogram @ 10-15% Mass Reduction **>$1.00 to ≤ $2.50** 

**Level #1D** Average Cost/Kilogram @ 15-20% Mass Reduction **>$2.50 to ≤ $4.88** 

**≤ $4.88**

**% M ass**  **Weight Low**  **High**
**Reduct. "kg"**  **"$/kg" "$/kg"**  **Level D, De-Contenting** 1. No Impact to Daily

Operation 2. Impact to Daily

Operation (feature, function, performance, etc)

**Reduct. "kg"**  **"$/kg" "$/kg"** 
0% 0.00

-

$

-

$ 0.00% 0.00%
1% 17.11

-

$

-

$ 0.00% 0.00%
2% 34.21

-

$

-

$ 0.00% 0.00%
3% 51.32

-

$

-

$ 0.00% 0.00%
4% 68.42

-

$

-

$ 0.00% 0.00%
5% 85.53

-

$ 1.00

$ 0.00% 0.51%
6% 102.63

-

$ 1.00

$ 0.00% 0.61%
7% 119.74

-

$ 1.00

$ 0.00% 0.72%
8% 136.84

-

$ 1.00

$ 0.00% 0.82%
9% 153.95

-

$ 1.00

$ 0.00% 0.92%
10% 171.05 1.00

$ 2.50

$ 1.02% 2.56%
11% 188.16 1.00

$ 2.50

$ 1.13% 2.82%
12% 205.26 1.00

$ 2.50

$ 1.23% 3.07%
14% 239.47 1.00

$ 2.50

$ 1.43% 3.58%
15% 256.58 1.00

$ 2.50

$ 1.54% 3.84%
16% 273.68 2.50

$ 4.88

$ 4.09% 7.99%
17% 290.79 2.50

$ 4.88

$ 4.35% 8.49%
18% 307.89 2.50

$ 4.88

$ 4.61% 8.99%
19% 325.00 2.50

$ 4.88

$ 4.86% 9.49%
20% 342.10 2.50

$ 4.88

$ 5.12% 9.99% $

- $1.00 $2.00 $3.00 $4.00 $5.00 $6.00

# Idea Binning Cost/Kilogram

Thresholds 2010 Toy ota Venza

-- Wh ite Vin# 4T3ZA3BB1AU036880 $25,063.00
FEV PR 41982

lOW

hIGH