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 System 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 

I

(x1000) tem

Subsystem

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

SUBSYSTEM ROLL-UP 52.07 2.04 8.24 62.35 0.44 6.84 5.52 1.11 13.90 - 76.25 - - - 57.02 2.27

09000064810d3b0c.xls

EPA Contract:EP-C-07-069 WA1-3 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 System C

3 08

4

5

6

7

Item

Subsystem

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 WA1-3 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 System C

3 08

4

5

6

7

Item

Subsystem

USD USD USD

 - - -

 - - -

 - - -

 - - -

 - - -

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment 

(X1000)

W TECHNOLOGY PACKAGE

8

9

10 09

11

12

13 23

14

15 24

16

 - - -

 - - -

 - - -

 - - -

 - - -

 - - -

 - - -

 - - -

 - - -

 - - -

09000064810d3b0c.xls

EPA Contract:EP-C-07-069 WA1-3 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

Wedge 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

Worm 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

Adhesives

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

Cylindrical

Needle

Spherical

Taper

2 Fluid

Oil

Air

Journal

3 Magnetic

4 Flexure

80 - Seals/Gaskets/Adhesives

90 - Bearings/Wheels/Pulley/Sprocket
5 Bushing

6 Wheels

7 Pulleys

8 Sprockets

All other commodity items 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

Weight 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

% Mass 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 Toyota Venza --White

Vin# 4T3ZA3BB1AU036880

$25,063.00

FEV PR 41982

lOW

hIGH