Page:1 of 6 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/21/2012

DRAFT

Material Labor Burden End Item 

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

0 1807 Power Electric Center (PEC) Subsystem

1 00 Assembly of Power Electric Center (PEC) Subsystem $ 0.91 $ 5.36 $ 0.83 $ 7.10 $ - $ - $ - $ - $ - $ - $ 7.10 $ - $ - $ - $ - $ - $ - $ -

2 01 Power Electronics Control Center $ 241.82 $ 33.15 $ 81.42 $ 356.39 $ 2.49 $ 24.95 $ 28.51 $ 14.26 $ 70.21 $ 0.12 $ 426.72 $ - $ - $ - $ - $ - $ - $ -

3 75 Bracket $ 2.47 $ 0.67 $ 1.05 $ 4.20 $ 0.05 $ 0.55 $ 0.57 $ 0.21 $ 1.39 $ - $ 5.59 $ - $ - $ - $ - $ - $ - $ -

4 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

5 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

BASE TECHNOLO

System 

ED&T/R&D

(x1000)

Sub-Subsystem Description Investment

(X1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Technology Level: Mild Hybrid, Start-Stop Technology

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers

Study Case#: 0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

6 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 0 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 0 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 0 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 0 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 0 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 0 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 0 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 0 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 0 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 0 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 0 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 0 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 0 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 0 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810e7549.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: 8/21/2012

DRAFT

Material Labor Burden End Item 

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

BASE TECHNOLO

System 

ED&T/R&D

(x1000)

Sub-Subsystem Description Investment

(X1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Technology Level: Mild Hybrid, Start-Stop Technology

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers

Study Case#: 0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

SUBSYSTEM ROLL-UP $ 245.20 $ 39.18 $ 83.29 $ 367.68 $ 2.54 $ 25.50 $ 29.08 $ 14.47 $ 71.60 $ 0.12 $ 439.40 $ - $ - $ - $ - $ - $ - $ -

09000064810e7549.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: 8/21/2012

DRAFT

0 1807 Power Electric Center (PEC) Subsystem

1 00

2 01

3 75

4 80

5 85

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 0.91 $ 5.36 $ 0.83 $ 7.10 $ - $ - $ - $ - $ - $ - $ 7.10 $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 241.82 $ 33.15 $ 81.42 $ 356.39 $ 2.49 $ 24.95 $ 28.51 $ 14.26 $ 70.21 $ 0.12 $ 426.72 $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 2.47 $ 0.67 $ 1.05 $ 4.20 $ 0.05 $ 0.55 $ 0.57 $ 0.21 $ 1.39 $ - $ 5.59 $ - $ -

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

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

BASE TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb 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

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

6 99

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

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

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

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

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

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

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

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

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

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

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

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

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

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

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

0 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810e7549.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: 8/21/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

BASE TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb 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

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - ###### $ 39.18 $ 83.29 $ 367.68 $ 2.54 $ 25.50 $ 29.08 $ 14.47 $ 71.60 $ 0.12 $ 439.40 $ - $ -

09000064810e7549.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: 8/21/2012

DRAFT

0 1807 Power Electric Center (PEC) Subsystem

1 00

2 01

3 75

4 80

5 85

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

$ -

$ -

$ -

$ -

$ -

Investment(X1

000)

6 99

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

0 0

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

0 0 $ -

09000064810e7549.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: 8/21/2012

DRAFT

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

Investment(X1

000)

$ -

09000064810e7549.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: 8/21/2012

DRAFT

Material Labor Burden End Item 

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

0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

1807 Power Electric Center (PEC) Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

1 00 Assembly of Power Electric Center (PEC) Subsystem $ 0.91 $ 5.36 $ 0.83 $ 7.10 $ - $ - $ - $ - $ - $ - $ 7.10 $ -

A Assembly of SGCM subsystem/PEB 18 07 00 - N0402- 01 1 Full 1 $ 0.91 $ 5.36 $ 0.83 $ 7.10 $ - $ - $ - $ - $ - $ - $ 7.10 $ -

2 01 Power Electronics Control Center $ 241.82 $ 33.15 $ 81.42 $ 356.39 $ 2.49 $ 24.95 $ 28.51 $ 14.26 $ 70.21 $ 0.12 $ 426.72 $ -

A 18 07 01 - N0402- 01 1 Full 1 $241.82 $ 33.15 $ 81.42 $ 356.39 $ 2.49 $ 24.95 $ 28.51 $ 14.26 $ 70.21 $ 0.12 $ 426.72 $ -

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Starter Generator Control Module (SGCM)/Power Eectroncis 

Board (PEB)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Part Number

System 

ED&T/R&D

(x1000)

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem

Technology Level: Mild Hybrid, Start-Stop Technology

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers

Study Case#: N0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

3 75 Bracket $ 2.47 $ 0.67 $ 1.05 $ 4.20 $ 0.05 $ 0.55 $ 0.57 $ 0.21 $ 1.39 $ - $ 5.59 $ -

A V Bracket, PEB (SGCM) 18 07 75 - N0402- 01 1 Full 1

Includes assembly labor and 

fastener cost to mount bracket to 

PEB

$ 2.47 $ 0.67 $ 1.05 $ 4.20 $ 0.05 $ 0.55 $ 0.57 $ 0.21 $ 1.39 $ - $ 5.59 $ -

4 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A V Nut, PEB to BIW 18 07 80 - N0402- 01 2 Full 1 PIA to Assembly of SGCM $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

B V Bolt, PEB to BIW 18 07 80 - N0402- 02 2 Full 1 PIA to Assembly of SGCM

C V Bolt, PEB Bracket (PEB to Mount Bracket) 18 07 80 - N0402- 03 7 Full 1 PIA to V Bracket, PEB 

D V Bolt 12-V Cable PEB ( Same for 36V Cable) 18 07 80 - N0402- 04 2 Full 1 PIA to Assembly of SGCM

E V Bolt 36-V PEB to Alternator 18 07 80 - N0402- 05 3 Full 1 PIA to Assembly of SGCM

F V Nut, Cables to PEB 18 07 80 - N0402- 06 5 Full 1 PIA to Assembly of SGCM

G V Bolt PEB Cover ( Bolt Assembly, washer, tinnerman) 18 07 80 - N0402- 07 3 Full 1 PIA to Assembly of SGCM

H V lock, PEB connetors 18 07 80 - N0402- 08 2 Full 1 PIA to Assembly of SGCM

I Nut -Ground to PEB (BIW) 18 07 80 - N0402- 09 1 Full 1 PIA to Assembly of SGCM

5 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

A V Cover SGCM 18 07 85 - N0402- 01 1 Full 1 PIA to SGCM/PEB $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

6 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

Board (PEB)

$ 245.20 $ 39.18 $ 83.29 $ 367.68 $ 2.54 $ 25.50 $ 29.08 $ 14.47 $ 71.60 $ 0.12 $ 439.40 $ -

No Complete Subsystem Quote 

09000064810e7549.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: 8/21/2012

DRAFT

Material Labor Burden End Item 

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

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Part Number

System 

ED&T/R&D

(x1000)

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem

Technology Level: Mild Hybrid, Start-Stop Technology

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers

Study Case#: N0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

NOTES:

1.

No Complete Subsystem Quote 

(Yes/No)

 = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

09000064810e7549.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: 8/21/2012

DRAFT

0

1807 Power Electric Center (PEC) Subsystem

1 00 Assembly of Power Electric Center (PEC) Subsystem

A Assembly of SGCM subsystem/PEB 18 07 00 - N0402- 01 1 Full 1

2 01 Power Electronics Control Center

A 18 07 01 - N0402- 01 1 Full 1

Starter Generator Control Module (SGCM)/Power Eectroncis 

Board (PEB)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Part Number

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Mild Hybrid, Start-Stop Technology

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers

Study Case#: N0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

3 75 Bracket

A V Bracket, PEB (SGCM) 18 07 75 - N0402- 01 1 Full 1

Includes assembly labor and 

fastener cost to mount bracket to 

PEB

4 80 Boltings

A V Nut, PEB to BIW 18 07 80 - N0402- 01 2 Full 1 PIA to Assembly of SGCM

B V Bolt, PEB to BIW 18 07 80 - N0402- 02 2 Full 1 PIA to Assembly of SGCM

C V Bolt, PEB Bracket (PEB to Mount Bracket) 18 07 80 - N0402- 03 7 Full 1 PIA to V Bracket, PEB 

D V Bolt 12-V Cable PEB ( Same for 36V Cable) 18 07 80 - N0402- 04 2 Full 1 PIA to Assembly of SGCM

E V Bolt 36-V PEB to Alternator 18 07 80 - N0402- 05 3 Full 1 PIA to Assembly of SGCM

F V Nut, Cables to PEB 18 07 80 - N0402- 06 5 Full 1 PIA to Assembly of SGCM

G V Bolt PEB Cover ( Bolt Assembly, washer, tinnerman) 18 07 80 - N0402- 07 3 Full 1 PIA to Assembly of SGCM

H V lock, PEB connetors 18 07 80 - N0402- 08 2 Full 1 PIA to Assembly of SGCM

I Nut -Ground to PEB (BIW) 18 07 80 - N0402- 09 1 Full 1 PIA to Assembly of SGCM

5 85 Sealing Elements

A V Cover SGCM 18 07 85 - N0402- 01 1 Full 1 PIA to SGCM/PEB

6 99 Miscellaneous

Board (PEB)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

No Complete Subsystem Quote $ - $ -

09000064810e7549.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: 8/21/2012

DRAFT

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Part Number

NEW TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV 

(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Mild Hybrid, Start-Stop Technology

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers

Study Case#: N0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

NOTES:

1.

No Complete Subsystem Quote 

(Yes/No)

 = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

Investment

(X1000)

Tooling 

(x1000)

09000064810e7549.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:1 of 2 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/21/2012

DRAFT

Material Labor Burden End Item 

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

0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

1807 Power Electric Center (PEC) Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

1 00 Assembly of Power Electric Center (PEC) Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

2 01 Power Electronics Control Center $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

3 75 Bracket $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

BASE TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Technology Level: Mild Hybrid, Start-Stop Technology

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

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

4 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

5 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

6 99 Miscellaneous $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

Complete Subsystem Quote 

(Yes/No) No

09000064810e7549.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:2 of 2 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/21/2012

DRAFT

0

1807 Power Electric Center (PEC) Subsystem

1 00 Assembly of Power Electric Center (PEC) Subsystem

2 01 Power Electronics Control Center

3 75 Bracket

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem BASE TECHNOLOGY GENERAL PART INFORMATION:

2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb

Item

Subsystem

BASE TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Mild Hybrid, Start-Stop Technology

Vehicle Class: Mid to Large Size Passenger Vehilce, 4-6 Passengers

Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

4 80 Boltings

5 85 Sealing Elements

6 99 Miscellaneous

NOTES:

1. = A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of 

the competing technology

Complete Subsystem Quote 

(Yes/No) No

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

09000064810e7549.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: OEM Assembly, Mark-up Covered by ICM

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Assembly of SGCM/PEB Subsystem Part Number: 180700-N0402-01 Weekly Component Volume: Packaging Specification: Not Applicable

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

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

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-50 1

Assemble SGCM/PEB into 

vehicle.

OEM Assembly, Mark-up 

Covered by ICM Not Applicable General Assembly-OEM VO Assembly, OEM, LC 113 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.87 $0.13 $1.00 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.00 $1.00 $0.00

2

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-51 1

Assemble 12 Volt Positive 

Lead and 36V Harness lead to 

PEB

OEM Assembly, Mark-up 

Covered by ICM Not Applicable General Assembly-OEM VO Assembly, OEM, LC 100 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.97 $0.15 $1.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.12 $1.12 $0.00

3

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-52 1

Assemble Start-Generator 

Wires (x3) to PEB

OEM Assembly, Mark-up 

Covered by ICM Not Applicable General Assembly-OEM VO Assembly, OEM, LC 92 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $1.06 $0.16 $1.22 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.22 $1.22 $0.00

Costs Broken Out In

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

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

4

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-53 1

Run-down Internal eyelet 

connections (x5)

OEM Assembly, Mark-up 

Covered by ICM Not Applicable General Assembly-OEM VO Assembly, OEM, LC 138 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.70 $0.11 $0.81 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.81 $0.81 $0.00

5

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-54 1 Install and rundown PEB cover OEM Assembly, Mark-up Covered by ICM Not Applicable General Assembly-OEM VO Assembly, OEM, LC 138 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.70 $0.11 $0.81 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.81 $0.81 $0.00

6

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-55 1

Install Chassis end PEB ground 

strap.

OEM Assembly, Mark-up 

Covered by ICM Not Applicable General Assembly-OEM VO Assembly, OEM, LC 277 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.35 $0.05 $0.41 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.41 $0.41 $0.00

7

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-56 1

Insaller SGCM/PEB connectors 

x3

OEM Assembly, Mark-up 

Covered by ICM Not Applicable General Assembly-OEM VO Assembly, OEM, LC 138 1 1 1 0.000 $0.00 $97.48 $15.00 $15.00 $0.00 $0.70 $0.11 $0.81 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.81 $0.81 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: OEM Assembly, Mark-up Covered by ICM

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Assembly of SGCM/PEB Subsystem Part Number: 180700-N0402-01 Weekly Component Volume: Packaging Specification: Not Applicable

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

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

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: OEM Assembly, Mark-up Covered by ICM

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Assembly of SGCM/PEB Subsystem Part Number: 180700-N0402-01 Weekly Component Volume: Packaging Specification: Not Applicable

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

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

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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 V Nut, PEB to BIW 180780-N0402-01 2 S $0.00 $0.05 $0.00 $0.10 $0.10

2 V Bolt, PEB to BIW 180780-N0402-02 2 S $0.00 $0.06 $0.00 $0.12 $0.12

V Bolt 12-V Cable PEB ( Same 

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

4

for 36V Cable) 180780-N0402-04 2 S $0.00 $0.04 $0.00 $0.08 $0.08

5 V Bolt 36-V PEB to Alternator 180780-N0402-05 3 S $0.00 $0.04 $0.00 $0.12 $0.12

6 V Nut, Cables to PEB 180780-N0402-06 5 S $0.00 $0.05 $0.00 $0.25 $0.25

7

V Bolt PEB Cover ( Bolt 

Assembly, washer, tinnerman) 180780-N0402-07 3 S $0.00 $0.06 $0.00 $0.18 $0.18

8 V lock, PEB connetors 180780-N0402-08 2 S $0.00 $0.02 $0.00 $0.04 $0.04

9 V-Nut -Ground to PEB (BIW) 180780-N0402-09 1 S $0.00 $0.02 $0.00 $0.02 $0.02

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

Material

$0.91

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $7.10

T1 or OEM Total Manufacturing Cost: $0.91 $5.36 $0.83 $7.10 $0.00 $0.00 $0.00 $0.00 $0.00 $7.10

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.00% 0.00% 0.00% 0.00% 0.00%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.00 $0.00 $0.00 $0.00 $0.00

Base Cost Impact to Vehicle: $0.91 $5.36 $0.83 $7.10 $0.00 $0.00 $0.00 $0.00 $0.00 $7.10 $0 $0

Packaging Cost: $0.00

3

1

Notes: 

a) Items 1,2, & 3 must a

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: OEM Assembly, Mark-up Covered by ICM

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Assembly of SGCM/PEB Subsystem Part Number: 180700-N0402-01 Weekly Component Volume: Packaging Specification: Not Applicable

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

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

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

Net Cost Impact to Vehicle: $7.10

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:

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-50

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-51

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-52

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

$0.87 $0.13 $1.00 $0.00 $0.00 $0.00 $0.00 $0.00 Manual Load and Rundown, 4 fasteners 5 2 10 100 47 4700 96 37.60 85% 113 31.96 32 1 1 32 1.0 1.0

$0.97 $0.15 $1.12 $0.00 $0.00 $0.00 $0.00 $0.00 Manual Install two cables into PEB, external manual rundown 2 places 5 2 10 100 47 4700 96 37.60 85% 113 31.96 36 1 1 36 1.0 1.0

$1.06 $0.16 $1.22 $0.00 $0.00 $0.00 $0.00 $0.00 Manual Install three cables (from starter-generator assembly) into PEB, external manual rundown 3 places 5 2 10 100 47 4700 96 37.60 85% 113 31.96 39 - 1 39 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

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-53

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-54

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-55

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-56

$0.70 $0.11 $0.81 $0.00 $0.00 $0.00 $0.00 $0.00 Manual install and run-downd five terminal eyelet nuts. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 30 - 1 26 1.0 1.0

$0.70 $0.11 $0.81 $0.00 $0.00 $0.00 $0.00 $0.00 Manual Install and rundown three cover attachment bolt-washer assemblies. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 44 - 1 26 1.0 1.0

$0.35 $0.05 $0.41 $0.00 $0.00 $0.00 $0.00 $0.00 Manual install and rundown ground strap to BIW. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 17 - 1 13 1.0 1.0

$0.70 $0.11 $0.81 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - - 1 26 1.0 1.0

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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

Note: 

Component installation would be 

balanced with other non related HEV 

component installs resulting in capacities 

being met at a per station work time of 

26 seconds.

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 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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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

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

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

V Nut, PEB to BIW 180780-N0402-01

V Bolt, PEB to BIW 180780-N0402-02

V Bolt 12-V Cable PEB ( Same 

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

$0.10

$0.12

V Bolt 12-V Cable PEB ( Same 

for 36V Cable) 180780-N0402-04

V Bolt 36-V PEB to Alternator 180780-N0402-05

V Nut, Cables to PEB 180780-N0402-06

V Bolt PEB Cover ( Bolt 

Assembly, washer, tinnerman) 180780-N0402-07

V lock, PEB connetors 180780-N0402-08

V-Nut -Ground to PEB (BIW) 180780-N0402-09

$0.08

$0.12

$0.25

$0.18

$0.04

$0.02

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$5.36 $0.83 $7.10 $0.00 $0.00 $0.00 $0.00 $0.00

$7.10

2

Notes: 

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

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-50

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-51

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-52

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

113 32.00 1.00

100 36.00 1.00

92 39.00 1.00

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-53

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-54

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-55

Starter Generator Control Module 

(SGCM)/Power Eectroncis Board (PEB) 180701-N0402-01-56

138 26.00 1.00

138 26.00 1.00

277 13.00 1.00

138 26.00 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! -

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! -

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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! -

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

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File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

V Nut, PEB to BIW 180780-N0402-01

V Bolt, PEB to BIW 180780-N0402-02

V Bolt 12-V Cable PEB ( Same 

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! -

V Bolt 12-V Cable PEB ( Same 

for 36V Cable) 180780-N0402-04

V Bolt 36-V PEB to Alternator 180780-N0402-05

V Nut, Cables to PEB 180780-N0402-06

V Bolt PEB Cover ( Bolt 

Assembly, washer, tinnerman) 180780-N0402-07

V lock, PEB connetors 180780-N0402-08

V-Nut -Ground to PEB (BIW) 180780-N0402-09

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:1 of 2 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/21/2012

DRAFT

Material Labor Burden End Item 

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

0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

180701 Starter-Generator Control Module/ Power Electronic Board (PEB) 

A V PEB Assembly $21.14 $15.12 $23.70 $59.95 $0.42 $4.20 $4.80 $2.40 $11.81 $0.12 $71.89

B V PEB Lower Base Module $92.72 $12.72 $42.62 $148.07 $1.04 $10.36 $11.85 $5.92 $29.17 $0.00 $177.24

C V Main Circuit Board $115.01 $1.05 $5.16 $121.22 $0.85 $8.49 $9.70 $4.85 $23.88 $0.00 $145.10

D Conn Module 8-pin $12.95 $4.27 $9.93 $27.14 $0.19 $1.90 $2.17 $1.09 $5.35 $0.00 $32.49

180703-N0402-01

180703-N0402-30

180703-N0402-63

180703-N0402-110

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

NEW TECHNOLOGY GENERAL PART INFORMATION:

 Mild Series Gasoline Hybrid

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description Part Number

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem

Technology Level: Mild Series Gasoline Hybrid

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )

$241.82 $ 33.15 $ 81.42 $ 356.39 $ 2.49 $ 24.95 $ 28.51 $ 14.26 $ 70.21 $ 0.12 $ 426.72 $ -

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

09000064810e7549.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:2 of 2 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/21/2012

DRAFT

0

180701 Starter-Generator Control Module/ Power Electronic Board (PEB) 

A V PEB Assembly

B V PEB Lower Base Module

C V Main Circuit Board

D Conn Module 8-pin

180703-N0402-01

180703-N0402-30

180703-N0402-63

180703-N0402-110

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

NEW TECHNOLOGY GENERAL PART INFORMATION:

 Mild Series Gasoline Hybrid

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

Technology Level: Mild Series Gasoline Hybrid

Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers

Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )

$ - $ -

$ - $ -

Investment

(X1000)

Tooling 

(x1000)

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

$ - $ -

09000064810e7549.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

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

Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid) Annual Component Volume: Shipping Method:

Component Description: V Power Electronics Box (PEB) Assembly Part Number: 180701-N0402-01 Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life: Production Year:

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 

Mark-up 

Rate

Total 

Mark-up 

Cost

.

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

.

1 . V PEB Assembly 180703-N0402-01 1 Final Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Elec. Assembly, MC 213 2 2 1 2.99 $0.00 $36.21 $125.00 $250.00 $0.00 $0.34 $1.17 $1.51 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

2 . V Bracket, PEB - Paint 180775-N0402-01 1 Paint T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Plating/Coating Operator Plate/Finish, SMS, MHC 480 1 1 1 2.99 $0.00 $40.84 $125.00 $125.00 $0.00 $0.09 $0.26 $0.35 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

3 . V Bracket, PEB - Washing 180775-N0402-02 1 Turbo Tunnel T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LMC 2400 1 1 1 2.99 $0.00 $38.55 $20.81 $20.81 $0.00 $0.02 $0.01 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

4 . V Bracket, PEB - Projection Welding 180775-N0402-03 1 Weldment T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Welding/Soldering Operator Mech. Assembly, MC 120 1 1 1 2.99 $0.00 $41.55 $125.00 $125.00 $0.00 $0.35 $1.04 $1.39 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

5 . V Bracket - PEB Stamped Material 180775-N0402-04 1 Vertical Stamping Press, Tonnage 800-1000 T1 Assembly, Mark-up Applied @ Bottom. MC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, MLS 643 0.5 1 1 5.03 $0.55 $42.73 $106.69 $106.69 $2.77 $0.03 $0.17 $2.97 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

6 . V PEB Module 180703-N0402-02 1 Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electromechanical Assembly Elec. Assembly, MC 136 6 2 1 19.67 $0.00 $36.21 $125.00 $250.00 $0.00 $1.60 $1.84 $3.44 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

7 . V PEB Cold Plate Cover Tube, Straight-Tube Stock 180770-N0402-01 1 Steel Tube, Swaged T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, SS 277 1 1 1 0.080 $0.00 $42.73 $42.91 $42.91 $0.34 $0.15 $0.15 $0.65 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Series Gasoline Hybrid

MARK-UP COSTS

9,574

10

47

450,000

1

450,000

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

Full Quote

Modification Quote

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

7 . V PEB Cold Plate Cover Tube, Straight-Tube Stock 180770-N0402-01 1 Steel Tube, Swaged T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, SS 277 1 1 1 0.080 $0.00 $42.73 $42.91 $42.91 $0.34 $0.15 $0.15 $0.65 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

8 . V PEB Cold Plate Cover Tube, 90 Degree-Tube Stock 180770-N0402-02 1 Steel Tube, Bent & Swaged T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Cut/Punch/Forming Operator Stamp/Form, SS 200 1 1 1 0.180 $0.00 $42.73 $42.91 $42.91 $0.82 $0.21 $0.21 $1.25 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

9 . V PEB Cold Plate Cover-Assembly 180706-N0402-01 1 Assemble cover & two (2) tubes T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech. Assembly, LC 167 2 2 1 0.510 $0.00 $38.55 $100.00 $200.00 $0.00 $0.46 $1.19 $1.65 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

10 . V PEB Cold Plate Cover-Wash 180706-N0402-02 1 Turbo Tunnel T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LMC 2769 1 1 1 0.510 $0.00 $38.55 $20.81 $20.81 $0.00 $0.01 $0.01 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

11 . V PEB Cold Plate Cover-Machined 180706-N0402-03 1 EC-300 - Pallet Size 300 mm square, 550 lb Capacity T1 Assembly, Mark-up Applied @ Bottom. Not Applicable CNC Operator CNC Machining, LC 147 2 2 1 0.510 $0.00 $36.98 $30.38 $60.76 $0.00 $0.50 $0.41 $0.92 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

12 . V PEB Cold Plate Cover - Heat Treat 180706-N0402-04 1 Heat Treat T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 384 0.25 1 1 0.510 $0.00 $47.72 $150.00 $150.00 $0.00 $0.03 $0.39 $0.42 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

13 . V PEB Cold Plate Cover-Die Cast 180706-N0402-05 1 Cold Chamber Die Casting Machine (1000-1800 Ton) T1 Assembly, Mark-up Applied @ Bottom. Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, MS 496 1 1 1 0.525 $1.10 $41.48 $197.05 $197.05 $0.58 $0.08 $0.40 $1.06 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

14 . V DC-DC Terminal Housing-Assembly 180705-N0402-01 1 Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech. Assembly, LC 327 1 1 1 0.420 $0.00 $38.55 $100.00 $100.00 $0.00 $0.12 $0.31 $0.42 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

15 . V DC-DC Terminal Housing-Wash 180705-N0402-02 1 Turbo Tunnel T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LMC 2769 1 1 1 0.420 $0.00 $38.55 $20.81 $20.81 $0.00 $0.01 $0.01 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

16 . V DC-DC Terminal Housing-Machining 180705-N0402-03 1 EC-300 - Pallet Size 300 mm square, 550 lb Capacity T1 Assembly, Mark-up Applied @ Bottom. Not Applicable CNC Operator CNC Machining, LC 122 2 2 1 0.420 $0.00 $36.98 $30.38 $60.76 $0.00 $0.61 $0.50 $1.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

17 . V DC-DC Terminal Housing - Heat Treat 180705-N0402-04 1 Heat Treat T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 311 0.25 1 1 0.420 $0.00 $47.72 $150.00 $150.00 $0.00 $0.04 $0.48 $0.52 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

18 . V DC-DC Terminal Housing-Die Cast 180705-N0402-05 1 Cold Chamber Die Casting Machine (1000-1800 Ton) T1 Assembly, Mark-up Applied @ Bottom. Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, MS 511 1 1 1 0.462 $1.10 $41.48 $197.05 $197.05 $0.51 $0.08 $0.39 $0.97 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

19 . V PEB MG Terminal Housing-Assembly 180705-N0402-06 1 Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech. Assembly, LC 189 1 1 1 0.485 $0.00 $38.55 $100.00 $100.00 $0.00 $0.20 $0.53 $0.73 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

20 . V PEB MG Terminal Housing-Cleaning 180705-N0402-07 1 Turbo Tunnel T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LMC 2769 1 1 1 0.485 $0.00 $38.55 $20.81 $20.81 $0.00 $0.01 $0.01 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

21 . V PEB MG Terminal Housing-Machining 180705-N0402-08 1 EC-400 - Pallet Size 400 mm square, 1000 lb Capacity T1 Assembly, Mark-up Applied @ Bottom. Not Applicable CNC Operator CNC Machining, LMC, Automatic Load 146 2 4 1 0.485 $0.00 $36.98 $46.82 $187.28 $0.00 $0.51 $1.28 $1.79 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

22 . V PEB MG Terminal Housing - Heat Treat 180705-N0402-09 1 Heat Treat T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 235 0.25 1 1 0.485 $0.00 $47.72 $150.00 $150.00 $0.00 $0.05 $0.64 $0.69 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

23 . V PEB MG Terminal Housing-Die Cast 180705-N0402-10 1 Cold Chamber Die Casting Machine (1000-1800 Ton) T1 Assembly, Mark-up Applied @ Bottom. Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, MS 468 1 1 1 0.509 $1.10 $41.48 $197.05 $197.05 $0.56 $0.09 $0.42 $1.07 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

24 . V PEB Sheet Metal Wrap Around Cover-Stamping 180706-N0402-06 1 Vertical Stamping Press, Tonnage 0-60 T1 Assembly, Mark-up Applied @ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals 176 0.5 1 1 0.926 $0.48 $42.73 $15.50 $15.50 $0.44 $0.12 $0.09 $0.65 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

25 . V PEB Base Module 180703-N0402-03 1 Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, MC 120 24 3 1 9.291 $0.00 $29.83 $125.00 $375.00 $0.00 $5.97 $3.13 $9.09 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

26 . V Copper Relay 5 Assembly 180703-N0402-04 1 Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech. Assembly, LC 240 1 1 1 0.078 $0.00 $38.55 $100.00 $100.00 $0.00 $0.16 $0.42 $0.58 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

27 . V Copper Relay 5 Wash 180703-N0402-05 1 Batch Washing, General agitation T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC 2769 1 1 1 0.077 $0.00 $38.55 $10.75 $10.75 $0.00 $0.01 $0.00 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

28 . V Copper Relay 5 Plating 180703-N0402-06 1 Plated T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Plating/Coating Operator Plate Elect., SMS, LMC 1200 1 1 1 0.077 $0.00 $40.84 $100.18 $100.18 $0.00 $0.03 $0.08 $0.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

29 . V Copper Relay 5 Material 180703-N0402-07 1 Vertical Stamping Press, Tonnage 0-60 T1 Assembly, Mark-up Applied @ Bottom. Copper-Pure, Wire Cut/Punch/Forming Operator Stamp/Form, Terminals 2118 0.5 1 1 0.077 $2.45 $42.73 $15.50 $15.50 $0.19 $0.01 $0.01 $0.20 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

30 . V Copper Relay 4 Assembly 180703-N0402-08 1 Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech. Assembly, LC 240 1 1 1 0.135 $0.00 $38.55 $100.00 $100.00 $0.00 $0.16 $0.42 $0.58 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

31 . V Copper Relay 4 Wash 180703-N0402-09 1 Batch Washing, General agitation T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC 2769 1 1 1 0.133 $0.00 $38.55 $10.75 $10.75 $0.00 $0.01 $0.00 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

32 . V Copper Relay 4 Material 180703-N0402-10 1 Vertical Stamping Press, Tonnage 0-60 T1 Assembly, Mark-up Applied @ Bottom. Copper-Pure, Wire Cut/Punch/Forming Operator Stamp/Form, Terminals 2118 0.5 1 1 0.832 $2.45 $42.73 $15.50 $15.50 $2.04 $0.01 $0.01 $2.06 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

33 . V Copper Relay 3 Assembly 180703-N0402-11 1 Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech. Assembly, LC 240 1 1 1 0.047 $0.00 $38.55 $100.00 $100.00 $0.00 $0.16 $0.42 $0.58 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

34 . V Copper Relay 3 Wash 180703-N0402-12 1 Batch Washing, General agitation T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC 3000 1 1 1 0.045 $0.00 $38.55 $10.75 $10.75 $0.00 $0.01 $0.00 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

35 . V Copper Relay 3 Material 180703-N0402-13 1 Vertical Stamping Press, Tonnage 0-60 T1 Assembly, Mark-up Applied @ Bottom. Copper-Pure, Wire Cut/Punch/Forming Operator Stamp/Form, Terminals 5143 0.5 1 1 0.184 $2.45 $42.73 $15.50 $15.50 $0.45 $0.00 $0.00 $0.46 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

36 . V Copper Relay 2 Assembly V Copper Relay 2 Assembly 180703-N0402-14 180703-N0402-14 1 Assembly Assembly T1 Assembly, Mark-up Applied @ Bottom. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Not Applicable General Assembly General Assembly Mech. Assembly, LC Mech. Assembly, LC 240 1 1 1 0.094 $0.00 $38.55 $100.00 $100.00 $100.00 $100.00 $0.00 $0.16 $0.42 $0.58 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

37 . V Copper Relay 2 Washed 180703-N0402-15 1 Batch Washing, General agitation T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC 2769 1 1 1 0.093 $0.00 $38.55 $10.75 $10.75 $0.00 $0.01 $0.00 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

38 . V Copper Relay 2 Material 180703-N0402-16 1 Vertical Stamping Press, Tonnage 0-60 T1 Assembly, Mark-up Applied @ Bottom. Copper-Pure, Wire Cut/Punch/Forming Operator Stamp/Form, Terminals 5143 0.5 1 1 0.723 $2.45 $42.73 $15.50 $15.50 $1.77 $0.00 $0.00 $1.78 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

39 . V Copper Relay 1 Washed 180703-N0402-17 1 Batch Washing, General agitation T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC 2769 1 1 1 0.090 $0.00 $38.55 $10.75 $10.75 $0.00 $0.01 $0.00 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

40 . V Copper Relay 1 Material 180703-N0402-18 1 Vertical Stamping Press, Tonnage 0-60 T1 Assembly, Mark-up Applied @ Bottom. Copper-Pure, Wire Cut/Punch/Forming Operator Stamp/Form, Terminals 6000 0.5 1 1 0.535 $2.45 $42.73 $15.50 $15.50 $1.31 $0.00 $0.00 $1.32 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

41 . V Main Circuit Board De-panel 180703-N0402-19 1

De-Panel-Router Station, In-Line, Complex geometries an/or vibration 

sensitive boards/inverta delta boards. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly De-Panel, In-Line, Router 229 1 1 1 0.809 $0.00 $29.83 $24.38 $24.38 $0.00 $0.13 $0.11 $0.24 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

42 . V Main Circuit Board w-Auto thru hole mnted w/Flex Connector 180703-N0402-20 1

Thru Hole Chip Placement Assembly Line, 1-Automated and 1 Manual 

workstation, Max 9 chips per side with automated equipment. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Thru Hole, Auto 204 2 2 1 0.809 $0.00 $29.83 $62.59 $125.18 $0.00 $0.29 $0.61 $0.91 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

43 . V Small Circuit Board GD114438-1-2 180703-N0402-21 1 Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, LC 3600 1 1 1 0.022 $0.00 $29.83 $100.00 $100.00 $0.00 $0.01 $0.03 $0.04 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

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

Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid) Annual Component Volume: Shipping Method:

Component Description: V Power Electronics Box (PEB) Assembly Part Number: 180701-N0402-01 Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life: Production Year:

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 

Mark-up 

Rate

Total 

Mark-up 

Cost

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Series Gasoline Hybrid

MARK-UP COSTS

9,574

10

47

450,000

1

450,000

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

Full Quote

Modification Quote

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

44 . V Small Circuit Board GD114438-1-2-Depannel 180703-N0402-22 1

De-Panel-Router Station, In-Line, Complex geometries an/or vibration 

sensitive boards/inverta delta boards. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly De-Panel, In-Line, Router 450 1 1 1 0.022 $0.00 $29.83 $24.38 $24.38 $0.00 $0.07 $0.05 $0.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

45 . V Copper Relay Piece 180703-N0402-23 4 Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech. Assembly, LC 554 2 2 1 0.002 $0.00 $38.55 $100.00 $200.00 $0.00 $0.14 $0.36 $0.50 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

46 . V Copper Relay Piece-Wash 180703-N0402-24 4 Batch Washing, General agitation T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC 2769 1 1 1 0.000 $0.00 $38.55 $10.75 $10.75 $0.00 $0.01 $0.00 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

47 . V Copper Relay Piece-Material 180703-N0402-25 4 Vertical Stamping Press, Tonnage 0-60 T1 Assembly, Mark-up Applied @ Bottom. Copper-Pure, Wire Cut/Punch/Forming Operator Stamp/Form, Terminals 3600 0.5 1 1 0.066 $2.45 $42.73 $15.50 $15.50 $0.16 $0.01 $0.00 $0.17 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

48 . V Cover PEB Unit 180706-N0402-07 1 Assembly w/Vent Cap T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech. Assembly, LC 450 1 1 1 1.230 $0.00 $38.55 $100.00 $100.00 $0.00 $0.09 $0.22 $0.31 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

49 . V Cover PEB Unit-washed 180706-N0402-08 1 Turbo Tunnel T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LMC 360 1 1 1 1.230 $0.00 $38.55 $20.81 $20.81 $0.00 $0.11 $0.06 $0.16 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

50 . V Cover PEB Unit-machined 180706-N0402-09 1 EC-400 - Pallet Size 400 mm square, 1000 lb Capacity T1 Assembly, Mark-up Applied @ Bottom. Not Applicable CNC Operator CNC Machining, LMC, Automatic Load 120 3 3 1 1.230 $0.00 $36.98 $46.82 $140.46 $0.00 $0.92 $1.17 $2.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

51 . V Cover PEB Unit - Heat Treat 180706-N0402-10 1 Heat Treat T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Heat Treat Operator Heat Treat, MLS, LMC 150 0.5 2 1 1.230 $0.00 $47.72 $150.00 $300.00 $0.00 $0.16 $2.00 $2.16 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

52 . V Cover PEB Unit-Cast-Material V Cover PEB Unit-Cast-Material 180706-N0402-11 180706-N0402-11 1 Cold Chamber Die Casting Machine (1000-1800 Ton) Cold Chamber Die Casting Machine (1000-1800 Ton) T1 Assembly, Mark-up Applied @ Bottom. T1 Assembly, Mark-up Applied @ Bottom. Aluminum-A380, Cast Aluminum-A380, Cast Mold/Cast/Sinter Operator Mold/Cast/Sinter Operator Diecast, MS Diecast, MS 172 1 1 1 1.242 $1.10 $41.48 $197.05 $197.05 $197.05 $197.05 $1.37 $0.24 $1.14 $2.75 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

. .

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

. .

1 . V Weld Nut - Projection PEB Bracket 180780-N0402-01 2 Commodity Pricing S $0.00 $0.01

2 . V Bolt PEB Bracket 180780-N0402-02 7 Commodity Pricing S $0.00 $0.03

3 . V PEB Ground Strap Asm 180780-N0402-03 1 Commodity Pricing S $0.00 $0.25

4 . V M6 Flange Nut 180780-N0402-04 1 Commodity Pricing S $0.00 $0.02

5 . V Bolt M6x15 Hex and Philips w lock washer 180780-N0402-05 4 Commodity Pricing S $0.00 $0.02

6 . V PEB Cold Plate Cover Dowel Pin 180780-N0402-06 2 Commodity Pricing S $0.00 $0.72

7 . V Bolt M6x15 Hex and Philips w lock washer 180780-N0402-07 10 Commodity Pricing S $0.00 $0.02

8 . V M6 Flange Nut 180780-N0402-08 3 Commodity Pricing S $0.00 $0.02

9 . V PEB MG Terminal Housing Stud 180780-N0402-09 1 Commodity Pricing S $0.00 $0.02

10 . V M6 Flange Nut 180780-N0402-10 3 Commodity Pricing S $0.00 $0.02

11 . V Screw 4 mm Pan Hd Philips 180780-N0402-11 11 Commodity Pricing S $0.00 $0.01

12 . V Copper Relay Insert 180780-N0402-12 1 Commodity Pricing S $0.00 $0.02

13 . V Copper Relay Insert 180780-N0402-13 1 Commodity Pricing S $0.00 $0.02

14 . V Copper Relay Insert 180780-N0402-14 1 Commodity Pricing S $0.00 $0.02

15 . V Copper Relay Insert 180780-N0402-15 1 Commodity Pricing S $0.00 $0.02

16 . V Ground Cable 180703-N0402-26 1 Commodity Pricing S $0.00 $0.41

17 . V 175A Fuse 180703-N0402-27 1 Commodity Pricing S $0.00 $1.20

18 . V Fuse Nut 180780-N0402-16 1 Commodity Pricing S $0.00 $0.03

19 . V Bolt, Short, Circuit Boards 180780-N0402-17 13 Commodity Pricing S $0.00 $0.10

20 . V Small Circuit Board GD114438-1-2-SMT 180703-N0402-28 1 Commodity Pricing S $0.00 $0.57

21 . V Capacitor - odd form 180703-N0402-29 2 Commodity Pricing S $0.00 $0.03

22 . V Bolt, Short, Circuit Boards 180780-N0402-18 3 Commodity Pricing S $0.00 $0.10

23 . V Copper Relay Insert 180780-N0402-19 4 Commodity Pricing S $0.00 $0.02

.

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or 

OEM for Final or Sub-Assembly. In addition component material cost is accounted for in 

T1 quote sheet. Thus component cost will only be included for Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier 

for Subassembly.

24 . V Seal, PEB Cover 180785-N0402-01 1 Commodity Pricing S $0.00 $0.15

25 . V Vent Cap PEB 8 pin Module 180799-N0402-01 1 Commodity Pricing S $0.00 $0.20

26 . V Stud PEB Cover 180780-N0402-20 1 Commodity Pricing S $0.00 $0.02

27 . V Bolt, Long, PEB Cover 180780-N0402-21 6 Commodity Pricing S $0.00 $0.02

28 . V Bolt Short, PEB Cover 180780-N0402-22 6 Commodity Pricing S $0.00 $0.02

29 . V Terminal Housing Vent Tube 180770-N0402-03 2 Commodity Pricing S $0.00 $0.12

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

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

Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid) Annual Component Volume: Shipping Method:

Component Description: V Power Electronics Box (PEB) Assembly Part Number: 180701-N0402-01 Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life: Production Year:

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 

Mark-up 

Rate

Total 

Mark-up 

Cost

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Series Gasoline Hybrid

MARK-UP COSTS

9,574

10

47

450,000

1

450,000

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

Full Quote

Modification Quote

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

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up

T1 or OEM Total Manufacturing Cost: $21.14 $15.12 $23.70 $59.95 $0.00 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.42 $4.20 $4.80 $2.40 $11.81

Base Cost Impact to Vehicle: $21.14 $15.12 $23.70 $59.95 $0.42 $4.20 $4.80 $2.40 $11.81

Packaging Cost:

Net Cost Impact to Vehicle:

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 In-transit

Inventory Requirements (Weeks)

Supplier, Customer and In-transit

Inventory Requirements (Parts)

Rack/Pallet Investment Amortization: $0.123 $246,600 0.00% 2,250,000 60 5.00% $450 548 84 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 0

Packaging Cost Total: $0.123

PACKAGING CALCULATIONS: 

Packaging Type: Option #1

Part Size: 375x 220 x 180

Parts/Layer:3x7

Number of Layers: 4

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

.

. V PEB Assembly 180703-N0402-01

. V Bracket, PEB - Paint 180775-N0402-01

. V Bracket, PEB - Washing 180775-N0402-02

. V Bracket, PEB - Projection Welding 180775-N0402-03

. V Bracket - PEB Stamped Material 180775-N0402-04

. V PEB Module 180703-N0402-02

. V PEB Cold Plate Cover Tube, Straight-Tube Stock 180770-N0402-01

GENERAL COMPONENT INFORMATION

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

T1 High Assembly Complexity

Stackable Totes (Flexcon)

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions "x1000 "

Investment Assumptions "x1000 "

Material Labor Burden

Total Mfg'ing Cost (Component/

Assembly)

End Item 

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

Total Markup Cost (Component/

Assembly)

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

ek

Shifts./ 

Day

Hrs./ 

Shift Hrs./ Wk Wks./ Yr. Hrs./ Yr.

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

Cycle Time/Operation "Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

$1.51 $1.51 $0.00 $0.34 $1.17 $1.51 $0.00 $0.00 $0.00 $0.00 $0.00 Final Assembly 5 2 10 100 47 4700 96 37.60 85% 113

$0.35 $0.35 $0.00 $0.09 $0.26 $0.35 $0.00 $0.00 $0.00 $0.00 $0.00 Paint 5 2 10 100 47 4700 96 37.60 85% 113

$0.02 $0.02 $0.00 $0.02 $0.01 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 Turbo Tunnel 5 2 10 100 47 4700 96 37.60 85% 113

$1.39 $1.39 $0.00 $0.35 $1.04 $1.39 $0.00 $0.00 $0.00 $0.00 $0.00 Weldment 5 2 10 100 47 4700 96 37.60 85% 113

$2.97 $2.97 $2.77 $0.03 $0.17 $2.97 $0.00 $0.00 $0.00 $0.00 $0.00 Vertical Stamping Press, Tonnage 800-1000 5 2 10 100 47 4700 96 37.60 85% 113

$3.44 $3.44 $0.00 $1.60 $1.84 $3.44 $0.00 $0.00 $0.00 $0.00 $0.00 Assembly 5 2 10 100 47 4700 96 37.60 85% 113

$0.65 $0.65 $0.34 $0.15 $0.15 $0.65 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 96 37.60 85% 113

Gross Mark-up Costs x Quantity Process Information

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

TOTAL COSTS TOOLING & INVESTMENT Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time 

North America

North America

FOB Ship Point

. V PEB Cold Plate Cover Tube, Straight-Tube Stock 180770-N0402-01

. V PEB Cold Plate Cover Tube, 90 Degree-Tube Stock 180770-N0402-02

. V PEB Cold Plate Cover-Assembly 180706-N0402-01

. V PEB Cold Plate Cover-Wash 180706-N0402-02

. V PEB Cold Plate Cover-Machined 180706-N0402-03

. V PEB Cold Plate Cover - Heat Treat 180706-N0402-04

. V PEB Cold Plate Cover-Die Cast 180706-N0402-05

. V DC-DC Terminal Housing-Assembly 180705-N0402-01

. V DC-DC Terminal Housing-Wash 180705-N0402-02

. V DC-DC Terminal Housing-Machining 180705-N0402-03

. V DC-DC Terminal Housing - Heat Treat 180705-N0402-04

. V DC-DC Terminal Housing-Die Cast 180705-N0402-05

. V PEB MG Terminal Housing-Assembly 180705-N0402-06

. V PEB MG Terminal Housing-Cleaning 180705-N0402-07

. V PEB MG Terminal Housing-Machining 180705-N0402-08

. V PEB MG Terminal Housing - Heat Treat 180705-N0402-09

. V PEB MG Terminal Housing-Die Cast 180705-N0402-10

. V PEB Sheet Metal Wrap Around Cover-Stamping 180706-N0402-06

. V PEB Base Module 180703-N0402-03

. V Copper Relay 5 Assembly 180703-N0402-04

. V Copper Relay 5 Wash 180703-N0402-05

. V Copper Relay 5 Plating 180703-N0402-06

. V Copper Relay 5 Material 180703-N0402-07

. V Copper Relay 4 Assembly 180703-N0402-08

. V Copper Relay 4 Wash 180703-N0402-09

. V Copper Relay 4 Material 180703-N0402-10

. V Copper Relay 3 Assembly 180703-N0402-11

. V Copper Relay 3 Wash 180703-N0402-12

. V Copper Relay 3 Material 180703-N0402-13

. V Copper Relay 2 Assembly 180703-N0402-14

$0.65 $0.65 $0.34 $0.15 $0.15 $0.65 $0.00 $0.00 $0.00 $0.00 $0.00 Steel Tube, Swaged 5 2 10 100 47 4700 96 37.60 85% 113

$1.25 $1.25 $0.82 $0.21 $0.21 $1.25 $0.00 $0.00 $0.00 $0.00 $0.00 Steel Tube, Bent & Swaged 5 2 10 100 47 4700 96 37.60 85% 113

$1.65 $1.65 $0.00 $0.46 $1.19 $1.65 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble cover & two (2) tubes 5 2 10 100 47 4700 96 37.60 85% 113

$0.02 $0.02 $0.00 $0.01 $0.01 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 Turbo Tunnel 5 2 10 100 47 4700 96 37.60 85% 113

$0.92 $0.92 $0.00 $0.50 $0.41 $0.92 $0.00 $0.00 $0.00 $0.00 $0.00 EC-300 - Pallet Size 300 mm square, 550 lb Capacity 5 2 10 100 47 4700 96 37.60 85% 113

$0.42 $0.42 $0.00 $0.03 $0.39 $0.42 $0.00 $0.00 $0.00 $0.00 $0.00 See file titled "V PEB Assembly Heat Treat Cost Calcs" for batch size calculation 5 2 10 100 47 4700 96 37.60 85% 113

$1.06 $1.06 $0.58 $0.08 $0.40 $1.06 $0.00 $0.00 $0.00 $0.00 $0.00 Premium of 10% added to cycle time to account for post-cast trim operation 5 2 10 100 47 4700 96 37.60 85% 113

$0.42 $0.42 $0.00 $0.12 $0.31 $0.42 $0.00 $0.00 $0.00 $0.00 $0.00 Assembly 5 2 10 100 47 4700 96 37.60 85% 113

$0.02 $0.02 $0.00 $0.01 $0.01 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 Turbo Tunnel 5 2 10 100 47 4700 96 37.60 85% 113

$1.10 $1.10 $0.00 $0.61 $0.50 $1.10 $0.00 $0.00 $0.00 $0.00 $0.00 EC-300 - Pallet Size 300 mm square, 550 lb Capacity 5 2 10 100 47 4700 96 37.60 85% 113

$0.52 $0.52 $0.00 $0.04 $0.48 $0.52 $0.00 $0.00 $0.00 $0.00 $0.00 See file titled "V PEB Assembly Heat Treat Cost Calcs" for batch size calculation 5 2 10 100 47 4700 96 37.60 85% 113

$0.97 $0.97 $0.51 $0.08 $0.39 $0.97 $0.00 $0.00 $0.00 $0.00 $0.00 Premium of 10% added to cycle time to account for post-cast trim operation 5 2 10 100 47 4700 96 37.60 85% 113

$0.73 $0.73 $0.00 $0.20 $0.53 $0.73 $0.00 $0.00 $0.00 $0.00 $0.00 Assembly 5 2 10 100 47 4700 96 37.60 85% 113

$0.02 $0.02 $0.00 $0.01 $0.01 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 Turbo Tunnel 5 2 10 100 47 4700 96 37.60 85% 113

$1.79 $1.79 $0.00 $0.51 $1.28 $1.79 $0.00 $0.00 $0.00 $0.00 $0.00 EC-400 - Pallet Size 400 mm square, 1000 lb Capacity 5 2 10 100 47 4700 96 37.60 85% 113

$0.69 $0.69 $0.00 $0.05 $0.64 $0.69 $0.00 $0.00 $0.00 $0.00 $0.00 See file titled "V PEB Assembly Heat Treat Cost Calcs" for batch size calculation 5 2 10 100 47 4700 96 37.60 85% 113

$1.07 $1.07 $0.56 $0.09 $0.42 $1.07 $0.00 $0.00 $0.00 $0.00 $0.00 Premium of 10% added to cycle time to account for post-cast trim operation 5 2 10 100 47 4700 96 37.60 85% 113

$0.65 $0.65 $0.44 $0.12 $0.09 $0.65 $0.00 $0.00 $0.00 $0.00 $0.00 Vertical Stamping Press, Tonnage 0-60 5 2 10 100 47 4700 96 37.60 85% 113

$9.09 $9.09 $0.00 $5.97 $3.13 $9.09 $0.00 $0.00 $0.00 $0.00 $0.00 Assembly 5 2 10 100 47 4700 96 37.60 85% 113

$0.58 $0.58 $0.00 $0.16 $0.42 $0.58 $0.00 $0.00 $0.00 $0.00 $0.00 Assembly 5 2 10 100 47 4700 96 37.60 85% 113

$0.02 $0.02 $0.00 $0.01 $0.00 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Washing, General agitation 5 2 10 100 47 4700 96 37.60 85% 113

$0.12 $0.12 $0.00 $0.03 $0.08 $0.12 $0.00 $0.00 $0.00 $0.00 $0.00 Plated 5 2 10 100 47 4700 96 37.60 85% 113

$0.20 $0.20 $0.19 $0.01 $0.01 $0.20 $0.00 $0.00 $0.00 $0.00 $0.00 Vertical Stamping Press, Tonnage 0-60 5 2 10 100 47 4700 96 37.60 85% 113

$0.58 $0.58 $0.00 $0.16 $0.42 $0.58 $0.00 $0.00 $0.00 $0.00 $0.00 Assembly 5 2 10 100 47 4700 96 37.60 85% 113

$0.02 $0.02 $0.00 $0.01 $0.00 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Washing, General agitation 5 2 10 100 47 4700 96 37.60 85% 113

$2.06 $2.06 $2.04 $0.01 $0.01 $2.06 $0.00 $0.00 $0.00 $0.00 $0.00 Vertical Stamping Press, Tonnage 0-60 5 2 10 100 47 4700 96 37.60 85% 113

$0.58 $0.58 $0.00 $0.16 $0.42 $0.58 $0.00 $0.00 $0.00 $0.00 $0.00 Assembly 5 2 10 100 47 4700 96 37.60 85% 113

$0.02 $0.02 $0.00 $0.01 $0.00 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Washing, General agitation 5 2 10 100 47 4700 96 37.60 85% 113

$0.46 $0.46 $0.45 $0.00 $0.00 $0.46 $0.00 $0.00 $0.00 $0.00 $0.00 Vertical Stamping Press, Tonnage 0-60 5 2 10 100 47 4700 96 37.60 85% 113

. V Copper Relay 2 Assembly 180703-N0402-14 $0.58 $0.58 $0.00 $0.16 $0.42 $0.58 $0.00 $0.00 $0.00 $0.00 $0.00 Assembly 5 2 10 100 47 4700 96 37.60 85% 113

. V Copper Relay 2 Washed 180703-N0402-15

. V Copper Relay 2 Material 180703-N0402-16

. V Copper Relay 1 Washed 180703-N0402-17

. V Copper Relay 1 Material 180703-N0402-18

. V Main Circuit Board De-panel 180703-N0402-19

. V Main Circuit Board w-Auto thru hole mnted w/Flex Connector 180703-N0402-20

. V Small Circuit Board GD114438-1-2 180703-N0402-21

$0.58 $0.58 $0.00 $0.16 $0.42 $0.58 $0.00 $0.00 $0.00 $0.00 $0.00 Assembly 5 2 10 100 47 4700 96 37.60 85% 113

$0.02 $0.02 $0.00 $0.01 $0.00 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Washing, General agitation 5 2 10 100 47 4700 96 37.60 85% 113

$1.78 $1.78 $1.77 $0.00 $0.00 $1.78 $0.00 $0.00 $0.00 $0.00 $0.00 Vertical Stamping Press, Tonnage 0-60 5 2 10 100 47 4700 96 37.60 85% 113

$0.02 $0.02 $0.00 $0.01 $0.00 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Washing, General agitation 5 2 10 100 47 4700 96 37.60 85% 113

$1.32 $1.32 $1.31 $0.00 $0.00 $1.32 $0.00 $0.00 $0.00 $0.00 $0.00 Vertical Stamping Press, Tonnage 0-60 5 2 10 100 47 4700 96 37.60 85% 113

$0.24 $0.24 $0.00 $0.13 $0.11 $0.24 $0.00 $0.00 $0.00 $0.00 $0.00 De-Panel-Router Station, In-Line, Complex geometries an/or vibration sensitive boards/inverta delta boards. 5 2 10 100 47 4700 96 37.60 85% 113

$0.91 $0.91 $0.00 $0.29 $0.61 $0.91 $0.00 $0.00 $0.00 $0.00 $0.00 Thru Hole Chip Placement Assembly Line, 1-Automated and 1 Manual workstation, Max 9 chips per side with automated equipment. 5 2 10 100 47 4700 96 37.60 85% 113

$0.04 $0.04 $0.00 $0.01 $0.03 $0.04 $0.00 $0.00 $0.00 $0.00 $0.00 Assembly 5 2 10 100 47 4700 96 37.60 85% 113

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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.

. V Small Circuit Board GD114438-1-2-Depannel 180703-N0402-22

. V Copper Relay Piece 180703-N0402-23

. V Copper Relay Piece-Wash 180703-N0402-24

. V Copper Relay Piece-Material 180703-N0402-25

. V Cover PEB Unit 180706-N0402-07

. V Cover PEB Unit-washed 180706-N0402-08

. V Cover PEB Unit-machined 180706-N0402-09

. V Cover PEB Unit - Heat Treat 180706-N0402-10

. V Cover PEB Unit-Cast-Material 180706-N0402-11

T1 High Assembly Complexity

Stackable Totes (Flexcon)

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions "x1000 "

Investment Assumptions "x1000 "

Material Labor Burden

Total Mfg'ing Cost (Component/

Assembly)

End Item 

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

Total Markup Cost (Component/

Assembly)

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

ek

Shifts./ 

Day

Hrs./ 

Shift Hrs./ Wk Wks./ Yr. Hrs./ Yr.

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

Cycle Time/Operation "Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Gross Mark-up Costs x Quantity Process Information

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

TOTAL COSTS TOOLING & INVESTMENT Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time 

North America

North America

FOB Ship Point

$0.12 $0.12 $0.00 $0.07 $0.05 $0.12 $0.00 $0.00 $0.00 $0.00 $0.00 De-Panel-Router Station, In-Line, Complex geometries an/or vibration sensitive boards/inverta delta boards. 5 2 10 100 47 4700 96 37.60 85% 113

$0.50 $2.00 $0.00 $0.56 $1.44 $2.00 $0.00 $0.00 $0.00 $0.00 $0.00 Assembly 5 2 10 100 47 4700 383 9.40 85% 451

$0.02 $0.07 $0.00 $0.06 $0.02 $0.07 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Washing, General agitation 5 2 10 100 47 4700 383 9.40 85% 451

$0.17 $0.69 $0.65 $0.02 $0.02 $0.69 $0.00 $0.00 $0.00 $0.00 $0.00 Vertical Stamping Press, Tonnage 0-60 5 2 10 100 47 4700 383 9.40 85% 451

$0.31 $0.31 $0.00 $0.09 $0.22 $0.31 $0.00 $0.00 $0.00 $0.00 $0.00 Assembly w/Vent Cap 5 2 10 100 47 4700 96 37.60 85% 113

$0.16 $0.16 $0.00 $0.11 $0.06 $0.16 $0.00 $0.00 $0.00 $0.00 $0.00 Turbo Tunnel 5 2 10 100 47 4700 96 37.60 85% 113

$2.10 $2.10 $0.00 $0.92 $1.17 $2.10 $0.00 $0.00 $0.00 $0.00 $0.00 EC-400 - Pallet Size 400 mm square, 1000 lb Capacity 5 2 10 100 47 4700 96 37.60 85% 113

$2.16 $2.16 $0.00 $0.16 $2.00 $2.16 $0.00 $0.00 $0.00 $0.00 $0.00 See file titled "V PEB Assembly Heat Treat Cost Calcs" for batch size calculation 5 2 10 100 47 4700 96 37.60 85% 113

. V Cover PEB Unit-Cast-Material 180706-N0402-11 $2.75 $2.75 $1.37 $0.24 $1.14 $2.75 $0.00 $0.00 $0.00 $0.00 $0.00 Premium of 10% added to cycle time to account for post-cast trim operation 5 2 10 100 47 4700 96 37.60 85% 113

.

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

.

. V Weld Nut - Projection PEB Bracket 180780-N0402-01

. V Bolt PEB Bracket 180780-N0402-02

. V PEB Ground Strap Asm 180780-N0402-03

. V M6 Flange Nut 180780-N0402-04

. V Bolt M6x15 Hex and Philips w lock washer 180780-N0402-05

. V PEB Cold Plate Cover Dowel Pin 180780-N0402-06

. V Bolt M6x15 Hex and Philips w lock washer 180780-N0402-07

. V M6 Flange Nut 180780-N0402-08

. V PEB MG Terminal Housing Stud 180780-N0402-09

. V M6 Flange Nut 180780-N0402-10

. V Screw 4 mm Pan Hd Philips 180780-N0402-11

. V Copper Relay Insert 180780-N0402-12

. V Copper Relay Insert 180780-N0402-13

. V Copper Relay Insert 180780-N0402-14

. V Copper Relay Insert 180780-N0402-15

. V Ground Cable 180703-N0402-26

. V 175A Fuse 180703-N0402-27

. V Fuse Nut 180780-N0402-16

. V Bolt, Short, Circuit Boards 180780-N0402-17

. V Small Circuit Board GD114438-1-2-SMT 180703-N0402-28

. V Capacitor - odd form 180703-N0402-29

. V Bolt, Short, Circuit Boards 180780-N0402-18

. V Copper Relay Insert 180780-N0402-19

.

$2.75 $2.75 $1.37 $0.24 $1.14 $2.75 $0.00 $0.00 $0.00 $0.00 $0.00 Premium of 10% added to cycle time to account for post-cast trim operation 5 2 10 100 47 4700 96 37.60 85% 113

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

$0.00 $0.02 $0.02 $0.02

$0.00 $0.21 $0.21 $0.21

$0.00 $0.25 $0.25 $0.25

$0.00 $0.02 $0.02 $0.02

$0.00 $0.08 $0.08 $0.08

$0.00 $1.44 $1.44 $1.44

$0.00 $0.20 $0.20 $0.20

$0.00 $0.06 $0.06 $0.06

$0.00 $0.02 $0.02 $0.02

$0.00 $0.06 $0.06 $0.06

$0.00 $0.11 $0.11 $0.11

$0.00 $0.02 $0.02 $0.02

$0.00 $0.02 $0.02 $0.02

$0.00 $0.02 $0.02 $0.02

$0.00 $0.02 $0.02 $0.02

$0.00 $0.41 $0.41 $0.41

$0.00 $1.20 $1.20 $1.20

$0.00 $0.03 $0.03 $0.03

$0.00 $1.30 $1.30 $1.30

$0.00 $0.57 $0.57 $0.57

$0.00 $0.06 $0.06 $0.06

$0.00 $0.30 $0.30 $0.30

$0.00 $0.08 $0.08 $0.08

. V Seal, PEB Cover 180785-N0402-01

. V Vent Cap PEB 8 pin Module 180799-N0402-01

. V Stud PEB Cover 180780-N0402-20

. V Bolt, Long, PEB Cover 180780-N0402-21

. V Bolt Short, PEB Cover 180780-N0402-22

. V Terminal Housing Vent Tube 180770-N0402-03

$0.00 $0.15 $0.15 $0.15

$0.00 $0.20 $0.20 $0.20

$0.00 $0.02 $0.02 $0.02

$0.00 $0.12 $0.12 $0.12

$0.00 $0.12 $0.12 $0.12

$0.00 $0.24 $0.24 $0.24

Material Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$21.14 $15.12 $23.70 $59.95 $0.00 $0.00 $0.00 $0.00 $0.00

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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.

T1 High Assembly Complexity

Stackable Totes (Flexcon)

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions "x1000 "

Investment Assumptions "x1000 "

Material Labor Burden

Total Mfg'ing Cost (Component/

Assembly)

End Item 

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

Total Markup Cost (Component/

Assembly)

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

ek

Shifts./ 

Day

Hrs./ 

Shift Hrs./ Wk Wks./ Yr. Hrs./ Yr.

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

Cycle Time/Operation "Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Gross Mark-up Costs x Quantity Process Information

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

TOTAL COSTS TOOLING & INVESTMENT Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time 

North America

North America

FOB Ship Point

$59.95 $59.95

$59.95

$71.77 $0 $0

3

1

2

Notes: 

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

Packaging Cost: $0.12

Net Cost Impact to Vehicle: $71.89

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

.

. V PEB Assembly 180703-N0402-01

. V Bracket, PEB - Paint 180775-N0402-01

. V Bracket, PEB - Washing 180775-N0402-02

. V Bracket, PEB - Projection Welding 180775-N0402-03

. V Bracket - PEB Stamped Material 180775-N0402-04

. V PEB Module 180703-N0402-02

. V PEB Cold Plate Cover Tube, Straight-Tube Stock 180770-N0402-01

GENERAL COMPONENT INFORMATION

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

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

Resulting Pieces/Hour

Resulting Cycle Time/ Part

"Sec.

Total Number of Direct Operators

31.96 34 1 1 34 1.0 2.0 213 16.90 2.00

31.96 75 1 10 75 1.0 1.0 480 7.50 1.00

31.96 15 1 10 15 1.0 1.0 2400 1.50 1.00

31.96 30 1 1 30 1.0 1.0 120 30.00 1.00

31.96 6 1 1 6 1.0 1.0 643 5.60 0.50

31.96 196 5 1 53 1.0 2.0 136 26.50 6.00

31.96 13 1 1 13 1.0 1.0 277 13.00 1.00

Minimum Calculated Cycles Time Project Process Requirement

. V PEB Cold Plate Cover Tube, Straight-Tube Stock 180770-N0402-01

. V PEB Cold Plate Cover Tube, 90 Degree-Tube Stock 180770-N0402-02

. V PEB Cold Plate Cover-Assembly 180706-N0402-01

. V PEB Cold Plate Cover-Wash 180706-N0402-02

. V PEB Cold Plate Cover-Machined 180706-N0402-03

. V PEB Cold Plate Cover - Heat Treat 180706-N0402-04

. V PEB Cold Plate Cover-Die Cast 180706-N0402-05

. V DC-DC Terminal Housing-Assembly 180705-N0402-01

. V DC-DC Terminal Housing-Wash 180705-N0402-02

. V DC-DC Terminal Housing-Machining 180705-N0402-03

. V DC-DC Terminal Housing - Heat Treat 180705-N0402-04

. V DC-DC Terminal Housing-Die Cast 180705-N0402-05

. V PEB MG Terminal Housing-Assembly 180705-N0402-06

. V PEB MG Terminal Housing-Cleaning 180705-N0402-07

. V PEB MG Terminal Housing-Machining 180705-N0402-08

. V PEB MG Terminal Housing - Heat Treat 180705-N0402-09

. V PEB MG Terminal Housing-Die Cast 180705-N0402-10

. V PEB Sheet Metal Wrap Around Cover-Stamping 180706-N0402-06

. V PEB Base Module 180703-N0402-03

. V Copper Relay 5 Assembly 180703-N0402-04

. V Copper Relay 5 Wash 180703-N0402-05

. V Copper Relay 5 Plating 180703-N0402-06

. V Copper Relay 5 Material 180703-N0402-07

. V Copper Relay 4 Assembly 180703-N0402-08

. V Copper Relay 4 Wash 180703-N0402-09

. V Copper Relay 4 Material 180703-N0402-10

. V Copper Relay 3 Assembly 180703-N0402-11

. V Copper Relay 3 Wash 180703-N0402-12

. V Copper Relay 3 Material 180703-N0402-13

. V Copper Relay 2 Assembly 180703-N0402-14

31.96 13 1 1 13 1.0 1.0 277 13.00 1.00

31.96 18 1 1 18 1.0 1.0 200 18.00 1.00

31.96 43 1 1 43 1.0 2.0 167 21.50 2.00

31.96 13 1 10 13 1.0 1.0 2769 1.30 1.00

31.96 49 1 1 49 1.0 2.0 147 24.50 2.00

31.96 27,000 1 2,881 27,000 1.0 1.0 384 9.37 0.25

31.96 40 1 6 44 1.0 1.0 496 7.26 1.00

31.96 11 1 1 11 1.0 1.0 327 11.00 1.00

31.96 13 1 10 13 1.0 1.0 2769 1.30 1.00

31.96 59 1 1 59 1.0 2.0 122 29.50 2.00

31.96 27,000 1 2,333 27,000 1.0 1.0 311 11.57 0.25

31.96 38 1 6 42 1.0 1.0 511 7.04 1.00

31.96 19 1 1 19 1.0 1.0 189 19.00 1.00

31.96 13 1 10 13 1.0 1.0 2769 1.30 1.00

31.96 99 1 1 99 1.0 4.0 146 24.63 2.00

31.96 27,000 1 1,759 27,000 1.0 1.0 235 15.35 0.25

31.96 42 1 6 46 1.0 1.0 468 7.70 1.00

31.96 21 1 1 21 1.0 1.0 176 20.50 0.50

31.96 648 8 1 90 1.0 3.0 120 30.00 24.00

31.96 15 1 1 15 1.0 1.0 240 15.00 1.00

31.96 13 1 10 13 1.0 1.0 2769 1.30 1.00

31.96 30 1 10 30 1.0 1.0 1200 3.00 1.00

31.96 2 1 1 2 1.0 1.0 2118 1.70 0.50

31.96 15 1 1 15 1.0 1.0 240 15.00 1.00

31.96 13 1 10 13 1.0 1.0 2769 1.30 1.00

31.96 2 1 1 2 1.0 1.0 2118 1.70 0.50

31.96 15 1 1 15 1.0 1.0 240 15.00 1.00

31.96 12 1 10 12 1.0 1.0 3000 1.20 1.00

31.96 1 1 1 1 1.0 1.0 5143 0.70 0.50

. V Copper Relay 2 Assembly 180703-N0402-14 31.96 15 1 1 15 1.0 1.0 240 15.00 1.00

. V Copper Relay 2 Washed 180703-N0402-15

. V Copper Relay 2 Material 180703-N0402-16

. V Copper Relay 1 Washed 180703-N0402-17

. V Copper Relay 1 Material 180703-N0402-18

. V Main Circuit Board De-panel 180703-N0402-19

. V Main Circuit Board w-Auto thru hole mnted w/Flex Connector 180703-N0402-20

. V Small Circuit Board GD114438-1-2 180703-N0402-21

31.96 15 1 1 15 1.0 1.0 240 15.00 1.00

31.96 13 1 10 13 1.0 1.0 2769 1.30 1.00

31.96 1 1 1 1 1.0 1.0 5143 0.70 0.50

31.96 13 1 10 13 1.0 1.0 2769 1.30 1.00

31.96 1 1 1 1 1.0 1.0 6000 0.60 0.50

31.96 16 1 1 16 1.0 1.0 229 15.70 1.00

31.96 35 1 1 35 1.0 2.0 204 17.65 2.00

31.96 1 1 1 1 1.0 1.0 3600 1.00 1.00

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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.

. V Small Circuit Board GD114438-1-2-Depannel 180703-N0402-22

. V Copper Relay Piece 180703-N0402-23

. V Copper Relay Piece-Wash 180703-N0402-24

. V Copper Relay Piece-Material 180703-N0402-25

. V Cover PEB Unit 180706-N0402-07

. V Cover PEB Unit-washed 180706-N0402-08

. V Cover PEB Unit-machined 180706-N0402-09

. V Cover PEB Unit - Heat Treat 180706-N0402-10

. V Cover PEB Unit-Cast-Material 180706-N0402-11

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

Resulting Pieces/Hour

Resulting Cycle Time/ Part

"Sec.

Total Number of Direct Operators

Minimum Calculated Cycles Time Project Process Requirement

31.96 8 1 1 8 1.0 1.0 450 8.00 1.00

7.99 13 1 1 13 1.0 2.0 554 6.50 2.00

7.99 13 1 10 13 1.0 1.0 2769 1.30 1.00

7.99 1 1 1 1 1.0 1.0 3600 1.00 0.50

31.96 8 1 1 8 1.0 1.0 450 8.00 1.00

31.96 10 1 1 10 1.0 1.0 360 10.00 1.00

31.96 90 1 1 90 1.0 3.0 120 30.00 3.00

31.96 27,000 1 562 27,000 1.0 2.0 150 24.02 0.50

. V Cover PEB Unit-Cast-Material 180706-N0402-11 31.96 38 1 2 42 1.0 1.0 172 20.90 1.00

.

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

.

. V Weld Nut - Projection PEB Bracket 180780-N0402-01

. V Bolt PEB Bracket 180780-N0402-02

. V PEB Ground Strap Asm 180780-N0402-03

. V M6 Flange Nut 180780-N0402-04

. V Bolt M6x15 Hex and Philips w lock washer 180780-N0402-05

. V PEB Cold Plate Cover Dowel Pin 180780-N0402-06

. V Bolt M6x15 Hex and Philips w lock washer 180780-N0402-07

. V M6 Flange Nut 180780-N0402-08

. V PEB MG Terminal Housing Stud 180780-N0402-09

. V M6 Flange Nut 180780-N0402-10

. V Screw 4 mm Pan Hd Philips 180780-N0402-11

. V Copper Relay Insert 180780-N0402-12

. V Copper Relay Insert 180780-N0402-13

. V Copper Relay Insert 180780-N0402-14

. V Copper Relay Insert 180780-N0402-15

. V Ground Cable 180703-N0402-26

. V 175A Fuse 180703-N0402-27

. V Fuse Nut 180780-N0402-16

. V Bolt, Short, Circuit Boards 180780-N0402-17

. V Small Circuit Board GD114438-1-2-SMT 180703-N0402-28

. V Capacitor - odd form 180703-N0402-29

. V Bolt, Short, Circuit Boards 180780-N0402-18

. V Copper Relay Insert 180780-N0402-19

.

31.96 38 1 2 42 1.0 1.0 172 20.90 1.00

. V Seal, PEB Cover 180785-N0402-01

. V Vent Cap PEB 8 pin Module 180799-N0402-01

. V Stud PEB Cover 180780-N0402-20

. V Bolt, Long, PEB Cover 180780-N0402-21

. V Bolt Short, PEB Cover 180780-N0402-22

. V Terminal Housing Vent Tube 180770-N0402-03

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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.

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

Resulting Pieces/Hour

Resulting Cycle Time/ Part

"Sec.

Total Number of Direct Operators

Minimum Calculated Cycles Time Project Process Requirement

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

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

Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid) Annual Component Volume: Shipping Method:

Component Description: V PEB Lower Base Module Part Number: 180701-N0402-30 Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life: Production Year:

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 

Mark-up 

Rate

Total 

Mark-up 

Cost

.

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

.

1 . V PEB Lower Base Module - Potting 180703-N0402-30 1 Potting T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, MC 308 1 1 1 9.291 $0.00 $29.83 $125.00 $125.00 $0.00 $0.10 $0.41 $0.50 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

2 . V PEB Lower Base Module - Wire Stitch Bonding 180703-N0402-31 1 Wire Bonding Machine, Auto Load T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Welding/Soldering Operator Wire Bonding Machine, Auto Load 157 4 2 4 9.291 $0.00 $41.55 $51.05 $408.40 $0.00 $1.06 $2.61 $3.67 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

3 . V PEB Lower Base Module Housing Assy 180705-N0402-11 1 Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech. Assembly, MC 117 12 3 4 3.255 $0.00 $38.55 $125.00 $1,500.00 $0.00 $3.94 $12.78 $16.72 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

4 . V PEB Lower Base Module Housing Assy Wash 180705-N0402-12 1 Rotary, Linear or Carousel Washers with dedicated jets with drying equipment T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment MHC 960 1 1 1 3.255 $0.00 $38.55 $77.95 $77.95 $0.00 $0.04 $0.08 $0.12 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

5 . V PEB Lower Base Module Housing Assy Machined 180705-N0402-13 1 EC-400 - Pallet Size 400 mm square, 1000 lb Capacity T1 Assembly, Mark-up Applied @ Bottom. Not Applicable CNC Operator CNC Machining, LMC, Automatic Load 115 8 16 1 3.255 $0.00 $36.98 $46.82 $749.12 $0.00 $2.58 $6.52 $9.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

6 . V PEB Lower Base Module Housing Assy - Heat Treat 180705-N0402-14 1 Vacuum Heat Treating T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Heat Treat Operator Heat Treat, MLS, MHC 141 1 4 1 3.255 $0.00 $47.72 $250.00 $1,000.00 $0.00 $0.34 $7.10 $7.44 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

9,574

10

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Series Gasoline Hybrid

MARK-UP COSTS

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 . V PEB Lower Base Module Housing Assy - Heat Treat 180705-N0402-14 1 Vacuum Heat Treating T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Heat Treat Operator Heat Treat, MLS, MHC 141 1 4 1 3.255 $0.00 $47.72 $250.00 $1,000.00 $0.00 $0.34 $7.10 $7.44 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

7 . V PEB Lower Base Module Housing Assy Cast Material 180705-N0402-15 1 Cold Chamber Die Casting Machine (2600-3800 Ton) T1 Assembly, Mark-up Applied @ Bottom. Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, LS 138 1 1 1 3.415 $1.10 $41.48 $301.91 $301.91 $3.76 $0.30 $2.20 $6.25 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

8 . V Capacitor- Housing-Glued 180705-N0402-16 1 Apply Adhesive T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech. Assembly, LC 212 1 1 1 0.006 $0.00 $38.55 $100.00 $100.00 $0.00 $0.18 $0.47 $0.65 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

9 . V Capacitor- Housing-Material 180705-N0402-17 1 Injection Molding Machines (55-150 Ton) T1 Assembly, Mark-up Applied @ Bottom. PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 1129 0.5 1 1 0.009 $1.46 $41.48 $16.39 $16.39 $0.01 $0.02 $0.01 $0.05 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

10 . V Inductor Cover - Small-Wash 180706-N0402-12 1 Batch Washing, General agitation T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC 2769 1 1 1 0.011 $0.00 $38.55 $10.75 $10.75 $0.00 $0.01 $0.00 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

11 . V Inductor Cover - Small-Material 180706-N0402-13 1 Vertical Stamping Press, Tonnage 0-60 T1 Assembly, Mark-up Applied @ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals 6000 0.5 1 1 0.013 $0.48 $42.73 $15.50 $15.50 $0.01 $0.00 $0.00 $0.01 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

12 . V Inductor Cover- Large-Wash 180706-N0402-14 1 Batch Washing, General agitation T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC 2769 1 1 1 0.026 $0.00 $38.55 $10.75 $10.75 $0.00 $0.01 $0.00 $0.02 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

13 . V Inductor Cover- Large-Material 180706-N0402-15 1 Vertical Stamping Press, Tonnage 0-60 T1 Assembly, Mark-up Applied @ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals 6000 0.5 1 1 0.091 $0.48 $42.73 $15.50 $15.50 $0.04 $0.00 $0.00 $0.05 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

14 . V Small Pad - Capacitor-Material 180799-N0402-02 1 Injection Molding Machines (55-150 Ton) T1 Assembly, Mark-up Applied @ Bottom. Thermoset-SBR Mold/Cast/Sinter Operator Inject. Mold, SS 2400 0.5 1 1 0.023 $1.32 $41.48 $16.39 $16.39 $0.03 $0.01 $0.01 $0.05 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

15 . V Large Pad - Capacitor-Material 180799-N0402-03 1 Injection Molding Machines (200-400 Ton) T1 Assembly, Mark-up Applied @ Bottom. Thermoset-SBR Mold/Cast/Sinter Operator Inject. Mold, SMS 1440 0.5 1 1 0.083 $1.32 $41.48 $28.80 $28.80 $0.11 $0.01 $0.02 $0.14 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

16 . V Capacitor Top Cover 180706-N0402-16 1 Press Inserts / Sleeves T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech. Assembly, MC 218 2 2 1 0.177 $0.00 $38.55 $125.00 $250.00 $0.00 $0.35 $1.15 $1.50 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

17 . V Capacitor Top Cover-Molded-Material 180706-N0402-17 1 Injection Molding Machines (1500-3000 Ton) T1 Assembly, Mark-up Applied @ Bottom. PPS-GF40, Inject. Mold/Cast/Sinter Operator Inject. Mold, LS 1490 0.5 1 1 0.214 $6.02 $41.48 $151.77 $151.77 $1.29 $0.01 $0.10 $1.40 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

18 . V PEB Mid Base Module Housing Assy 180705-N0402-18 1 Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech. Assembly, MC 147 4 4 1 2.420 $0.00 $38.55 $125.00 $500.00 $0.00 $1.05 $3.40 $4.45 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

19 . V PEB Mid Base Module Housing Raw Material 180705-N0402-19 1 Injection Molding Machines (1500-3000 Ton) T1 Assembly, Mark-up Applied @ Bottom. PPS-GF35-MF30, Inject. Mold/Cast/Sinter Operator Inject. Mold, LS 113 2 1 1 1.348 $3.86 $41.48 $151.77 $151.77 $5.20 $0.73 $1.34 $7.27 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

20 . V Terminal Block PEB Coil Cavity-Weld 180703-N0402-32 2 Weldment T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Welding/Soldering Operator Mech. Assembly, LC 400 2 2 1 0.050 $0.00 $41.55 $100.00 $200.00 $0.00 $0.21 $0.50 $0.71 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

21 . V Terminal Block PEB Coil Cavity-Wash 180703-N0402-33 2 Batch Washing, General agitation T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC 4500 1 1 1 0.050 $0.00 $38.55 $10.75 $10.75 $0.00 $0.01 $0.00 $0.01 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

22 . V Terminal Block PEB Coil Cavity-Stamp 180703-N0402-34 2 Vertical Stamping Press, Tonnage 0-60 T1 Assembly, Mark-up Applied @ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals 6000 0.5 1 1 0.050 $0.48 $42.73 $15.50 $15.50 $0.02 $0.00 $0.00 $0.03 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

23 . V Terminal Block PEB - Fuse Connect - Coil Cavit-Welded 180703-N0402-35 1 Weldment T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Welding/Soldering Operator Mech. Assembly, LC 240 1 1 1 0.010 $0.00 $41.55 $100.00 $100.00 $0.00 $0.17 $0.42 $0.59 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

24 . V Terminal Block PEB - Fuse Connect - Coil Cavit-Washed 180703-N0402-36 1 Batch Washing, General agitation T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC 4500 1 1 1 0.010 $0.00 $38.55 $10.75 $10.75 $0.00 $0.01 $0.00 $0.01 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

25 . V Terminal Block PEB - Fuse Connect - Coil Cavit-Stamped 180703-N0402-37 1 Vertical Stamping Press, Tonnage 0-60 T1 Assembly, Mark-up Applied @ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals 6000 0.5 1 1 0.010 $0.48 $42.73 $15.50 $15.50 $0.00 $0.00 $0.00 $0.01 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

26 . V Terminal Block PEB - Mtr/Alt Pass Through-Weld 180703-N0402-38 3 Weldment T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Welding/Soldering Operator Mech. Assembly, LC 400 2 2 1 0.050 $0.00 $41.55 $100.00 $200.00 $0.00 $0.21 $0.50 $0.71 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

27 . V Terminal Block PEB - Mtr/Alt Pass Through-Wash 180703-N0402-39 3 Batch Washing, General agitation T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC 4500 1 1 1 0.050 $0.00 $38.55 $10.75 $10.75 $0.00 $0.01 $0.00 $0.01 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

28 . V Terminal Block PEB - Mtr/Alt Pass Through-Stamp 180703-N0402-40 3 Vertical Stamping Press, Tonnage 0-60 T1 Assembly, Mark-up Applied @ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals 6000 0.5 1 1 0.088 $0.48 $42.73 $15.50 $15.50 $0.04 $0.00 $0.00 $0.05 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

29 . V Terminal PEB main to heat sink plate-Wash 180703-N0402-41 4 Batch Washing, General agitation T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC 4500 1 1 1 0.060 $0.00 $38.55 $10.75 $10.75 $0.00 $0.01 $0.00 $0.01 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

30 . V Terminal PEB main to heat sink plate-Plate 180703-N0402-42 4 Plated T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Plating/Coating Operator Plate Elect., SMS, LMC 1440 1 1 1 0.060 $0.00 $40.84 $100.18 $100.18 $0.00 $0.03 $0.07 $0.10 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

31 . V Terminal PEB main to heat sink plate-Stamp 180703-N0402-43 4 Vertical Stamping Press, Tonnage 0-60 T1 Assembly, Mark-up Applied @ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals 6000 0.5 1 1 0.070 $0.48 $42.73 $15.50 $15.50 $0.03 $0.00 $0.00 $0.04 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

32 . V Terminal Plate Capcitor Anode-Welding 180703-N0402-44 1 Weldment T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Welding/Soldering Operator Mech. Assembly, LC 200 1 1 1 0.290 $0.00 $41.55 $100.00 $100.00 $0.00 $0.21 $0.50 $0.71 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

33 . V Terminal Plate Capcitor Anode-Wash 180703-N0402-45 1 Batch Washing, General agitation T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC 3600 1 1 1 0.290 $0.00 $38.55 $10.75 $10.75 $0.00 $0.01 $0.00 $0.01 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

34 . V Terminal Plate Capcitor Anode-Plate 180703-N0402-46 1 Plated T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Plating/Coating Operator Plate Elect., SMS, LMC 1333 1 1 1 0.290 $0.00 $40.84 $100.18 $100.18 $0.00 $0.03 $0.08 $0.11 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

35 . V Terminal Plate Capcitor Anode-Stamp V Terminal Plate Capcitor Anode-Stamp 180703-N0402-47 180703-N0402-47 1 Vertical Stamping Press, Tonnage 0-60 Vertical Stamping Press, Tonnage 0-60 T1 Assembly, Mark-up Applied @ Bottom. T1 Assembly, Mark-up Applied @ Bottom. LC-GSteel-1000S, Coil LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Cut/Punch/Forming Operator Stamp/Form, Terminals Stamp/Form, Terminals 2118 0.5 1 1 0.343 $0.48 $42.73 $15.50 $15.50 $0.16 $0.01 $0.01 $0.18 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

36 . V Terminal Plate Capcitor Cathode-Weld 180703-N0402-48 1 Weldment T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Welding/Soldering Operator Mech. Assembly, LC 200 1 1 1 0.320 $0.00 $41.55 $100.00 $100.00 $0.00 $0.21 $0.50 $0.71 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

37 . V Terminal Plate Capcitor Cathode-Wash 180703-N0402-49 1 Batch Washing, General agitation T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Washing Equipment, LC 3600 1 1 1 0.320 $0.00 $38.55 $10.75 $10.75 $0.00 $0.01 $0.00 $0.01 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

38 . V Terminal Plate Capcitor Cathode-Plated 180703-N0402-50 1 Plated T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Plating/Coating Operator Plate Elect., SMS, LMC 1333 1 1 1 0.320 $0.00 $40.84 $100.18 $100.18 $0.00 $0.03 $0.08 $0.11 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

39 . V Terminal Plate Capcitor Cathode-Stamped 180703-N0402-51 1 Vertical Stamping Press, Tonnage 0-60 T1 Assembly, Mark-up Applied @ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals 6000 0.5 1 1 0.403 $0.48 $42.73 $15.50 $15.50 $0.19 $0.00 $0.00 $0.20 0.00% 0.00% 0.00% 0.00% 0.00% $0.00

. .

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

. .

1 . V Capacitor- - Asm. 180703-N0402-52 1 Commodity Pricing S "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly. $0.00 $0.11

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

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

Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid) Annual Component Volume: Shipping Method:

Component Description: V PEB Lower Base Module Part Number: 180701-N0402-30 Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life: Production Year:

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 

Mark-up 

Rate

Total 

Mark-up 

Cost

9,574

10

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Series Gasoline Hybrid

MARK-UP COSTS

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)

2 . V Capacitor- - Blue 180703-N0402-53 1 Commodity Pricing S $0.00 $0.10

3 . V Inductor Coil - Small 180703-N0402-54 1 Commodity Pricing S $0.00 $3.12

4 . V Inductor Coil - Large 180703-N0402-55 1 Commodity Pricing S $0.00 $3.63

5 . V Bolt, Long, Small Board 180780-N0402-23 3 Commodity Pricing S $0.00 $0.02

6 . V Capacitor - Oval 63V 180703-N0402-56 1 Commodity Pricing S $0.00 $19.60

7 . V Capacitor - Cylinder 80V 180703-N0402-57 3 Commodity Pricing S $0.00 $8.10

8 . V Capacitor - Square 75V 180703-N0402-58 1 Commodity Pricing S $0.00 $19.80

9 . V Seal - Capacitor Cover 180785-N0402-02 1 Commodity Pricing S $0.00 $0.07

10 . V Anti-Crush Sleeve PEB mid housing 180799-N0402-04 7 Commodity Pricing S $0.00 $0.01

11 . V Bolt, Long, Small Board 180780-N0402-24 6 Commodity Pricing S $0.00 $0.02

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or 

OEM for Final or Sub-Assembly. In addition component material cost is accounted for in 

T1 quote sheet. Thus component cost will only be included for Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier 

for Subassembly.

11 . V Bolt, Long, Small Board 180780-N0402-24 6 Commodity Pricing S $0.00 $0.02

12 . V Bolt, Long, Small Board 180780-N0402-25 8 Commodity Pricing S $0.00 $0.02

13 . V 5 Pin Terminal Set PEB Mid base Module Housing A 180703-N0402-59 8 Commodity Pricing S $0.00 $0.10

14 . V Terminal Nut press-weld 180780-N0402-26 2 Commodity Pricing S $0.00 $0.02

15 . V Stud Terminal PEB 180780-N0402-27 2 Commodity Pricing S $0.00 $0.04

16 . V Stud Terminal PEB 180780-N0402-28 1 Commodity Pricing S $0.00 $0.04

17 . V Terminal Nut press-weld 180780-N0402-29 3 Commodity Pricing S $0.00 $0.02

18 . V Stud Terminal PEB 180780-N0402-30 3 Commodity Pricing S $0.00 $0.04

19 . V Terminal Nut press-weld 180780-N0402-31 1 Commodity Pricing S $0.00 $0.02

20 . V Terminal Nut press-weld 180780-N0402-32 1 Commodity Pricing S $0.00 $0.02

21 . V Threaded Insert steel PEB mid housing 180780-N0402-33 6 Commodity Pricing S $0.00 $0.02

22 . V Threaded Insert brass PEB mid housing 180780-N0402-34 9 Commodity Pricing S $0.00 $0.03

23 . V Anti-Crush Sleeve PEB mid housing 180799-N0402-05 5 Commodity Pricing S $0.00 $0.01

24 . V Threaded Insert steel PEB mid housing 180703-N0402-60 6 Commodity Pricing S $0.00 $0.02

25 . V Large O-ring, Module 180785-N0402-03 1 Commodity Pricing S $0.00 $0.16

26 . V Small O-ring, Module 180785-N0402-04 1 Commodity Pricing S $0.00 $0.09

27 . V Bolt, Long, Small Board 180780-N0402-35 2 Commodity Pricing S $0.00 $0.02

28 . V Bolt , Long, Ciruit Boards 180780-N0402-36 10 Commodity Pricing S $0.00 $0.01

29 . V Bolt, Long, Small Board 180780-N0402-37 2 Commodity Pricing S $0.00 $0.02

30 . V Bolt , Long, Ciruit Boards 180780-N0402-38 1 Commodity Pricing S $0.00 $0.01

31 . V Bolt, Long, Small Board 180780-N0402-39 3 Commodity Pricing S $0.00 $0.02

32 . V Bolt, Long, Small Board 180780-N0402-40 2 Commodity Pricing S $0.00 $0.02

33 . V Bolt, Long, Small Board 180780-N0402-41 2 Commodity Pricing S $0.00 $0.02

34 . V Bolt, Long, Small Board 180780-N0402-42 1 Commodity Pricing S $0.00 $0.02

35 . V Bolt , Long, Ciruit Boards 180780-N0402-43 2 Commodity Pricing S $0.00 $0.01

36 . V Bolt, Long, Small Board 180780-N0402-44 1 Commodity Pricing S $0.00 $0.02

37 . V Bolt , Long, Ciruit Boards 180780-N0402-45 8 Commodity Pricing S $0.00 $0.01

38 . V PEB Heat Transfer Plate A 180703-N0402-61 1 Commodity Pricing S $0.00 $2.00

39 . V PEB Heat Transfer Plate B 180703-N0402-62 1 Commodity Pricing S $0.00 $6.00

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up

T1 or OEM Total Manufacturing Cost: $92.72 $12.72 $42.62 $148.07 $0.00 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $1.04 $10.36 $11.85 $5.92 $29.17

Base Cost Impact to Vehicle: $92.72 $12.72 $42.62 $148.07 $1.04 $10.36 $11.85 $5.92 $29.17

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

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

Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid) Annual Component Volume: Shipping Method:

Component Description: V PEB Lower Base Module Part Number: 180701-N0402-30 Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life: Production Year:

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 

Mark-up 

Rate

Total 

Mark-up 

Cost

9,574

10

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Series Gasoline Hybrid

MARK-UP COSTS

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)

Packaging Cost:

Net Cost Impact to Vehicle:

Packaging Lump Sum 

Cost per Pallet /Rack

Total Number of Pallets/ Racks

Required

Number of Parts per Pallet/ Rack

Supplier, Customer and In-transit

Inventory Requirements (Weeks)

Supplier, Customer and In-transit

Inventory Requirements (Parts)

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years 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 In-transit

Inventory Requirements (Weeks)

Supplier, Customer and In-transit

Inventory Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 548 105 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Parts/Layer:

Number of Layers:

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

.

. V PEB Lower Base Module - Potting 180703-N0402-30

. V PEB Lower Base Module - Wire Stitch Bonding 180703-N0402-31

. V PEB Lower Base Module Housing Assy 180705-N0402-11

. V PEB Lower Base Module Housing Assy Wash 180705-N0402-12

. V PEB Lower Base Module Housing Assy Machined 180705-N0402-13

. V PEB Lower Base Module Housing Assy - Heat Treat 180705-N0402-14

GENERAL COMPONENT INFORMATION

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

T1 High Assembly Complexity

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions "x1000 "

Investment Assumptions "x1000 "

Material Labor Burden

Total Mfg'ing Cost (Component/

Assembly)

End Item 

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

Total Markup Cost (Component/

Assembly)

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

ek

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."

$0.50 $0.50 $0.00 $0.10 $0.41 $0.50 $0.00 $0.00 $0.00 $0.00 $0.00 Potting 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$3.67 $3.67 $0.00 $1.06 $2.61 $3.67 $0.00 $0.00 $0.00 $0.00 $0.00 Wire Bonding Machine, Auto Load 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$16.72 $16.72 $0.00 $3.94 $12.78 $16.72 $0.00 $0.00 $0.00 $0.00 $0.00 Assembly 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.12 $0.12 $0.00 $0.04 $0.08 $0.12 $0.00 $0.00 $0.00 $0.00 $0.00 Rotary, Linear or Carousel Washers with dedicated jets with drying equipment 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$9.10 $9.10 $0.00 $2.58 $6.52 $9.10 $0.00 $0.00 $0.00 $0.00 $0.00 EC-400 - Pallet Size 400 mm square, 1000 lb Capacity 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$7.44 $7.44 $0.00 $0.34 $7.10 $7.44 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 96 37.60 85% 113 31.96

North America

North America

FOB Ship Point

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information

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

TOTAL COSTS TOOLING & INVESTMENT

. V PEB Lower Base Module Housing Assy - Heat Treat 180705-N0402-14

. V PEB Lower Base Module Housing Assy Cast Material 180705-N0402-15

. V Capacitor- Housing-Glued 180705-N0402-16

. V Capacitor- Housing-Material 180705-N0402-17

. V Inductor Cover - Small-Wash 180706-N0402-12

. V Inductor Cover - Small-Material 180706-N0402-13

. V Inductor Cover- Large-Wash 180706-N0402-14

. V Inductor Cover- Large-Material 180706-N0402-15

. V Small Pad - Capacitor-Material 180799-N0402-02

. V Large Pad - Capacitor-Material 180799-N0402-03

. V Capacitor Top Cover 180706-N0402-16

. V Capacitor Top Cover-Molded-Material 180706-N0402-17

. V PEB Mid Base Module Housing Assy 180705-N0402-18

. V PEB Mid Base Module Housing Raw Material 180705-N0402-19

. V Terminal Block PEB Coil Cavity-Weld 180703-N0402-32

. V Terminal Block PEB Coil Cavity-Wash 180703-N0402-33

. V Terminal Block PEB Coil Cavity-Stamp 180703-N0402-34

. V Terminal Block PEB - Fuse Connect - Coil Cavit-Welded 180703-N0402-35

. V Terminal Block PEB - Fuse Connect - Coil Cavit-Washed 180703-N0402-36

. V Terminal Block PEB - Fuse Connect - Coil Cavit-Stamped 180703-N0402-37

. V Terminal Block PEB - Mtr/Alt Pass Through-Weld 180703-N0402-38

. V Terminal Block PEB - Mtr/Alt Pass Through-Wash 180703-N0402-39

. V Terminal Block PEB - Mtr/Alt Pass Through-Stamp 180703-N0402-40

. V Terminal PEB main to heat sink plate-Wash 180703-N0402-41

. V Terminal PEB main to heat sink plate-Plate 180703-N0402-42

. V Terminal PEB main to heat sink plate-Stamp 180703-N0402-43

. V Terminal Plate Capcitor Anode-Welding 180703-N0402-44

. V Terminal Plate Capcitor Anode-Wash 180703-N0402-45

. V Terminal Plate Capcitor Anode-Plate 180703-N0402-46

. V Terminal Plate Capcitor Anode-Stamp 180703-N0402-47

$7.44 $7.44 $0.00 $0.34 $7.10 $7.44 $0.00 $0.00 $0.00 $0.00 $0.00 See file titled "V PEB Assembly Heat Treat Cost Calcs" for batch size calculation 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$6.25 $6.25 $3.76 $0.30 $2.20 $6.25 $0.00 $0.00 $0.00 $0.00 $0.00 Premium of 10% added to cycle time to account for post-cast trim operation 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.65 $0.65 $0.00 $0.18 $0.47 $0.65 $0.00 $0.00 $0.00 $0.00 $0.00 Apply Adhesive 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.05 $0.05 $0.01 $0.02 $0.01 $0.05 $0.00 $0.00 $0.00 $0.00 $0.00 Injection Molding Machines (55-150 Ton) 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.02 $0.02 $0.00 $0.01 $0.00 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Washing, General agitation 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.01 $0.01 $0.01 $0.00 $0.00 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 Vertical Stamping Press, Tonnage 0-60 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.02 $0.02 $0.00 $0.01 $0.00 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Washing, General agitation 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.05 $0.05 $0.04 $0.00 $0.00 $0.05 $0.00 $0.00 $0.00 $0.00 $0.00 Vertical Stamping Press, Tonnage 0-60 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.05 $0.05 $0.03 $0.01 $0.01 $0.05 $0.00 $0.00 $0.00 $0.00 $0.00 Injection Molding Machines (55-150 Ton) 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.14 $0.14 $0.11 $0.01 $0.02 $0.14 $0.00 $0.00 $0.00 $0.00 $0.00 Injection Molding Machines (200-400 Ton) 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$1.50 $1.50 $0.00 $0.35 $1.15 $1.50 $0.00 $0.00 $0.00 $0.00 $0.00 Press Inserts / Sleeves 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$1.40 $1.40 $1.29 $0.01 $0.10 $1.40 $0.00 $0.00 $0.00 $0.00 $0.00 Injection Molding Machines (1500-3000 Ton) 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$4.45 $4.45 $0.00 $1.05 $3.40 $4.45 $0.00 $0.00 $0.00 $0.00 $0.00 Assembly 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$7.27 $7.27 $5.20 $0.73 $1.34 $7.27 $0.00 $0.00 $0.00 $0.00 $0.00 Injection Molding Machines (1500-3000 Ton) 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.71 $1.42 $0.00 $0.42 $1.00 $1.42 $0.00 $0.00 $0.00 $0.00 $0.00 Weldment 5 2 10 100 47 4700 191 18.80 85% 225 15.98

$0.01 $0.02 $0.00 $0.02 $0.00 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Washing, General agitation 5 2 10 100 47 4700 191 18.80 85% 225 15.98

$0.03 $0.06 $0.05 $0.01 $0.01 $0.06 $0.00 $0.00 $0.00 $0.00 $0.00 Vertical Stamping Press, Tonnage 0-60 5 2 10 100 47 4700 191 18.80 85% 225 15.98

$0.59 $0.59 $0.00 $0.17 $0.42 $0.59 $0.00 $0.00 $0.00 $0.00 $0.00 Weldment 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.01 $0.01 $0.00 $0.01 $0.00 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Washing, General agitation 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.01 $0.01 $0.00 $0.00 $0.00 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 Vertical Stamping Press, Tonnage 0-60 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.71 $2.12 $0.00 $0.62 $1.50 $2.12 $0.00 $0.00 $0.00 $0.00 $0.00 Weldment 5 2 10 100 47 4700 287 12.53 85% 338 10.65

$0.01 $0.03 $0.00 $0.03 $0.01 $0.03 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Washing, General agitation 5 2 10 100 47 4700 287 12.53 85% 338 10.65

$0.05 $0.15 $0.13 $0.01 $0.01 $0.15 $0.00 $0.00 $0.00 $0.00 $0.00 Vertical Stamping Press, Tonnage 0-60 5 2 10 100 47 4700 287 12.53 85% 338 10.65

$0.01 $0.04 $0.00 $0.03 $0.01 $0.04 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Washing, General agitation 5 2 10 100 47 4700 383 9.40 85% 451 7.99

$0.10 $0.39 $0.00 $0.11 $0.28 $0.39 $0.00 $0.00 $0.00 $0.00 $0.00 Plated 5 2 10 100 47 4700 383 9.40 85% 451 7.99

$0.04 $0.16 $0.13 $0.01 $0.01 $0.16 $0.00 $0.00 $0.00 $0.00 $0.00 Vertical Stamping Press, Tonnage 0-60 5 2 10 100 47 4700 383 9.40 85% 451 7.99

$0.71 $0.71 $0.00 $0.21 $0.50 $0.71 $0.00 $0.00 $0.00 $0.00 $0.00 Weldment 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.01 $0.01 $0.00 $0.01 $0.00 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Washing, General agitation 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.11 $0.11 $0.00 $0.03 $0.08 $0.11 $0.00 $0.00 $0.00 $0.00 $0.00 Plated 5 2 10 100 47 4700 96 37.60 85% 113 31.96

. V Terminal Plate Capcitor Anode-Stamp 180703-N0402-47 $0.18 $0.18 $0.16 $0.01 $0.01 $0.18 $0.00 $0.00 $0.00 $0.00 $0.00 Vertical Stamping Press, Tonnage 0-60 5 2 10 100 47 4700 96 37.60 85% 113 31.96

. V Terminal Plate Capcitor Cathode-Weld 180703-N0402-48

. V Terminal Plate Capcitor Cathode-Wash 180703-N0402-49

. V Terminal Plate Capcitor Cathode-Plated 180703-N0402-50

. V Terminal Plate Capcitor Cathode-Stamped 180703-N0402-51

.

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

.

. V Capacitor- - Asm. 180703-N0402-52

$0.18 $0.18 $0.16 $0.01 $0.01 $0.18 $0.00 $0.00 $0.00 $0.00 $0.00 Vertical Stamping Press, Tonnage 0-60 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.71 $0.71 $0.00 $0.21 $0.50 $0.71 $0.00 $0.00 $0.00 $0.00 $0.00 Weldment 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.01 $0.01 $0.00 $0.01 $0.00 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 Batch Washing, General agitation 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.11 $0.11 $0.00 $0.03 $0.08 $0.11 $0.00 $0.00 $0.00 $0.00 $0.00 Plated 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.20 $0.20 $0.19 $0.00 $0.00 $0.20 $0.00 $0.00 $0.00 $0.00 $0.00 Vertical Stamping Press, Tonnage 0-60 5 2 10 100 47 4700 96 37.60 85% 113 31.96

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

$0.00 $0.11 $0.11 $0.11

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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.

. V Capacitor- - Blue 180703-N0402-53

. V Inductor Coil - Small 180703-N0402-54

. V Inductor Coil - Large 180703-N0402-55

. V Bolt, Long, Small Board 180780-N0402-23

. V Capacitor - Oval 63V 180703-N0402-56

. V Capacitor - Cylinder 80V 180703-N0402-57

. V Capacitor - Square 75V 180703-N0402-58

. V Seal - Capacitor Cover 180785-N0402-02

. V Anti-Crush Sleeve PEB mid housing 180799-N0402-04

. V Bolt, Long, Small Board 180780-N0402-24

T1 High Assembly Complexity

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions "x1000 "

Investment Assumptions "x1000 "

Material Labor Burden

Total Mfg'ing Cost (Component/

Assembly)

End Item 

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

Total Markup Cost (Component/

Assembly)

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

ek

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."

North America

North America

FOB Ship Point

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information

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

TOTAL COSTS TOOLING & INVESTMENT

$0.00 $0.10 $0.10 $0.10

$0.00 $3.12 $3.12 $3.12

$0.00 $3.63 $3.63 $3.63

$0.00 $0.06 $0.06 $0.06

$0.00 $19.60 $19.60 $19.60

$0.00 $24.30 $24.30 $24.30

$0.00 $19.80 $19.80 $19.80

$0.00 $0.07 $0.07 $0.07

$0.00 $0.07 $0.07 $0.07

. V Bolt, Long, Small Board 180780-N0402-24 $0.00 $0.12 $0.12 $0.12

. V Bolt, Long, Small Board 180780-N0402-25

. V 5 Pin Terminal Set PEB Mid base Module Housing A 180703-N0402-59

. V Terminal Nut press-weld 180780-N0402-26

. V Stud Terminal PEB 180780-N0402-27

. V Stud Terminal PEB 180780-N0402-28

. V Terminal Nut press-weld 180780-N0402-29

. V Stud Terminal PEB 180780-N0402-30

. V Terminal Nut press-weld 180780-N0402-31

. V Terminal Nut press-weld 180780-N0402-32

. V Threaded Insert steel PEB mid housing 180780-N0402-33

. V Threaded Insert brass PEB mid housing 180780-N0402-34

. V Anti-Crush Sleeve PEB mid housing 180799-N0402-05

. V Threaded Insert steel PEB mid housing 180703-N0402-60

. V Large O-ring, Module 180785-N0402-03

. V Small O-ring, Module 180785-N0402-04

. V Bolt, Long, Small Board 180780-N0402-35

. V Bolt , Long, Ciruit Boards 180780-N0402-36

. V Bolt, Long, Small Board 180780-N0402-37

. V Bolt , Long, Ciruit Boards 180780-N0402-38

. V Bolt, Long, Small Board 180780-N0402-39

. V Bolt, Long, Small Board 180780-N0402-40

. V Bolt, Long, Small Board 180780-N0402-41

. V Bolt, Long, Small Board 180780-N0402-42

. V Bolt , Long, Ciruit Boards 180780-N0402-43

. V Bolt, Long, Small Board 180780-N0402-44

. V Bolt , Long, Ciruit Boards 180780-N0402-45

. V PEB Heat Transfer Plate A 180703-N0402-61

. V PEB Heat Transfer Plate B 180703-N0402-62

$0.00 $0.12 $0.12 $0.12

$0.00 $0.16 $0.16 $0.16

$0.00 $0.80 $0.80 $0.80

$0.00 $0.04 $0.04 $0.04

$0.00 $0.08 $0.08 $0.08

$0.00 $0.04 $0.04 $0.04

$0.00 $0.06 $0.06 $0.06

$0.00 $0.12 $0.12 $0.12

$0.00 $0.02 $0.02 $0.02

$0.00 $0.02 $0.02 $0.02

$0.00 $0.12 $0.12 $0.12

$0.00 $0.27 $0.27 $0.27

$0.00 $0.05 $0.05 $0.05

$0.00 $0.12 $0.12 $0.12

$0.00 $0.16 $0.16 $0.16

$0.00 $0.09 $0.09 $0.09

$0.00 $0.04 $0.04 $0.04

$0.00 $0.10 $0.10 $0.10

$0.00 $0.04 $0.04 $0.04

$0.00 $0.01 $0.01 $0.01

$0.00 $0.06 $0.06 $0.06

$0.00 $0.04 $0.04 $0.04

$0.00 $0.04 $0.04 $0.04

$0.00 $0.02 $0.02 $0.02

$0.00 $0.02 $0.02 $0.02

$0.00 $0.02 $0.02 $0.02

$0.00 $0.08 $0.08 $0.08

$0.00 $2.00 $2.00 $2.00

$0.00 $6.00 $6.00 $6.00

Material Labor Burden TMC Scrape SG&A Profit ED&T Mark-up Material Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$92.72 $12.72 $42.62 $148.07 $0.00 $0.00 $0.00 $0.00 $0.00

$148.07 $148.07

$148.07

$177.24 $0 $0

3

1

2

Notes: 

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

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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.

T1 High Assembly Complexity

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions "x1000 "

Investment Assumptions "x1000 "

Material Labor Burden

Total Mfg'ing Cost (Component/

Assembly)

End Item 

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

Total Markup Cost (Component/

Assembly)

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

ek

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."

North America

North America

FOB Ship Point

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information

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

TOTAL COSTS TOOLING & INVESTMENT

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $177.24

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

.

. V PEB Lower Base Module - Potting 180703-N0402-30

. V PEB Lower Base Module - Wire Stitch Bonding 180703-N0402-31

. V PEB Lower Base Module Housing Assy 180705-N0402-11

. V PEB Lower Base Module Housing Assy Wash 180705-N0402-12

. V PEB Lower Base Module Housing Assy Machined 180705-N0402-13

. V PEB Lower Base Module Housing Assy - Heat Treat 180705-N0402-14

GENERAL COMPONENT INFORMATION

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

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

Resulting Pieces/Hour

Resulting Cycle Time/ Part

"Sec.

Total Number of Direct Operators

 12 1 1 12 1.0 1.0 308 11.70 1.00

 166 4 1 46 4.0 2.0 157 23.00 4.00

 347 4 1 92 4.0 3.0 117 30.67 12.00

 15 1 4 15 1.0 1.0 960 3.75 1.00

 502 1 1 502 1.0 16.0 115 31.36 8.00

 27,000 1 264 27,000 1.0 4.0 141 25.57 1.00

Project Process Requirement

. V PEB Lower Base Module Housing Assy - Heat Treat 180705-N0402-14

. V PEB Lower Base Module Housing Assy Cast Material 180705-N0402-15

. V Capacitor- Housing-Glued 180705-N0402-16

. V Capacitor- Housing-Material 180705-N0402-17

. V Inductor Cover - Small-Wash 180706-N0402-12

. V Inductor Cover - Small-Material 180706-N0402-13

. V Inductor Cover- Large-Wash 180706-N0402-14

. V Inductor Cover- Large-Material 180706-N0402-15

. V Small Pad - Capacitor-Material 180799-N0402-02

. V Large Pad - Capacitor-Material 180799-N0402-03

. V Capacitor Top Cover 180706-N0402-16

. V Capacitor Top Cover-Molded-Material 180706-N0402-17

. V PEB Mid Base Module Housing Assy 180705-N0402-18

. V PEB Mid Base Module Housing Raw Material 180705-N0402-19

. V Terminal Block PEB Coil Cavity-Weld 180703-N0402-32

. V Terminal Block PEB Coil Cavity-Wash 180703-N0402-33

. V Terminal Block PEB Coil Cavity-Stamp 180703-N0402-34

. V Terminal Block PEB - Fuse Connect - Coil Cavit-Welded 180703-N0402-35

. V Terminal Block PEB - Fuse Connect - Coil Cavit-Washed 180703-N0402-36

. V Terminal Block PEB - Fuse Connect - Coil Cavit-Stamped 180703-N0402-37

. V Terminal Block PEB - Mtr/Alt Pass Through-Weld 180703-N0402-38

. V Terminal Block PEB - Mtr/Alt Pass Through-Wash 180703-N0402-39

. V Terminal Block PEB - Mtr/Alt Pass Through-Stamp 180703-N0402-40

. V Terminal PEB main to heat sink plate-Wash 180703-N0402-41

. V Terminal PEB main to heat sink plate-Plate 180703-N0402-42

. V Terminal PEB main to heat sink plate-Stamp 180703-N0402-43

. V Terminal Plate Capcitor Anode-Welding 180703-N0402-44

. V Terminal Plate Capcitor Anode-Wash 180703-N0402-45

. V Terminal Plate Capcitor Anode-Plate 180703-N0402-46

. V Terminal Plate Capcitor Anode-Stamp 180703-N0402-47

 27,000 1 264 27,000 1.0 4.0 141 25.57 1.00

 71 1 3 79 1.0 1.0 138 26.18 1.00

 17 1 1 17 1.0 1.0 212 17.00 1.00

 51 1 16 51 1.0 1.0 1129 3.19 0.50

 13 1 10 13 1.0 1.0 2769 1.30 1.00

 1 1 1 1 1.0 1.0 6000 0.60 0.50

 13 1 10 13 1.0 1.0 2769 1.30 1.00

 1 1 1 1 1.0 1.0 6000 0.60 0.50

 15 1 10 15 1.0 1.0 2400 1.50 0.50

 15 1 6 15 1.0 1.0 1440 2.50 0.50

 33 1 1 33 1.0 2.0 218 16.50 2.00

 29 1 12 29 1.0 1.0 1490 2.42 0.50

 98 1 1 98 1.0 4.0 147 24.50 4.00

 64 1 2 64 1.0 1.0 113 31.75 2.00

 18 1 1 18 1.0 2.0 400 9.00 2.00

 8 1 10 8 1.0 1.0 4500 0.80 1.00

 1 1 1 1 1.0 1.0 6000 0.60 0.50

 15 1 1 15 1.0 1.0 240 15.00 1.00

 8 1 10 8 1.0 1.0 4500 0.80 1.00

 1 1 1 1 1.0 1.0 6000 0.60 0.50

 18 1 1 18 1.0 2.0 400 9.00 2.00

 8 1 10 8 1.0 1.0 4500 0.80 1.00

 1 1 1 1 1.0 1.0 6000 0.60 0.50

 8 1 10 8 1.0 1.0 4500 0.80 1.00

 25 1 10 25 1.0 1.0 1440 2.50 1.00

 1 1 1 1 1.0 1.0 6000 0.60 0.50

 18 1 1 18 1.0 1.0 200 18.00 1.00

 10 1 10 10 1.0 1.0 3600 1.00 1.00

 27 1 10 27 1.0 1.0 1333 2.70 1.00

. V Terminal Plate Capcitor Anode-Stamp 180703-N0402-47 2 1 1 2 1.0 1.0 2118 1.70 0.50

. V Terminal Plate Capcitor Cathode-Weld 180703-N0402-48

. V Terminal Plate Capcitor Cathode-Wash 180703-N0402-49

. V Terminal Plate Capcitor Cathode-Plated 180703-N0402-50

. V Terminal Plate Capcitor Cathode-Stamped 180703-N0402-51

.

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

.

. V Capacitor- - Asm. 180703-N0402-52

 2 1 1 2 1.0 1.0 2118 1.70 0.50

 18 1 1 18 1.0 1.0 200 18.00 1.00

 10 1 10 10 1.0 1.0 3600 1.00 1.00

 27 1 10 27 1.0 1.0 1333 2.70 1.00

 1 1 1 1 1.0 1.0 6000 0.60 0.50

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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.

. V Capacitor- - Blue 180703-N0402-53

. V Inductor Coil - Small 180703-N0402-54

. V Inductor Coil - Large 180703-N0402-55

. V Bolt, Long, Small Board 180780-N0402-23

. V Capacitor - Oval 63V 180703-N0402-56

. V Capacitor - Cylinder 80V 180703-N0402-57

. V Capacitor - Square 75V 180703-N0402-58

. V Seal - Capacitor Cover 180785-N0402-02

. V Anti-Crush Sleeve PEB mid housing 180799-N0402-04

. V Bolt, Long, Small Board 180780-N0402-24

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

Resulting Pieces/Hour

Resulting Cycle Time/ Part

"Sec.

Total Number of Direct Operators

Project Process Requirement

. V Bolt, Long, Small Board 180780-N0402-24

. V Bolt, Long, Small Board 180780-N0402-25

. V 5 Pin Terminal Set PEB Mid base Module Housing A 180703-N0402-59

. V Terminal Nut press-weld 180780-N0402-26

. V Stud Terminal PEB 180780-N0402-27

. V Stud Terminal PEB 180780-N0402-28

. V Terminal Nut press-weld 180780-N0402-29

. V Stud Terminal PEB 180780-N0402-30

. V Terminal Nut press-weld 180780-N0402-31

. V Terminal Nut press-weld 180780-N0402-32

. V Threaded Insert steel PEB mid housing 180780-N0402-33

. V Threaded Insert brass PEB mid housing 180780-N0402-34

. V Anti-Crush Sleeve PEB mid housing 180799-N0402-05

. V Threaded Insert steel PEB mid housing 180703-N0402-60

. V Large O-ring, Module 180785-N0402-03

. V Small O-ring, Module 180785-N0402-04

. V Bolt, Long, Small Board 180780-N0402-35

. V Bolt , Long, Ciruit Boards 180780-N0402-36

. V Bolt, Long, Small Board 180780-N0402-37

. V Bolt , Long, Ciruit Boards 180780-N0402-38

. V Bolt, Long, Small Board 180780-N0402-39

. V Bolt, Long, Small Board 180780-N0402-40

. V Bolt, Long, Small Board 180780-N0402-41

. V Bolt, Long, Small Board 180780-N0402-42

. V Bolt , Long, Ciruit Boards 180780-N0402-43

. V Bolt, Long, Small Board 180780-N0402-44

. V Bolt , Long, Ciruit Boards 180780-N0402-45

. V PEB Heat Transfer Plate A 180703-N0402-61

. V PEB Heat Transfer Plate B 180703-N0402-62

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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.

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

Resulting Pieces/Hour

Resulting Cycle Time/ Part

"Sec.

Total Number of Direct Operators

Project Process Requirement

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

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

Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 High Assembly Complexity

System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid) Annual Component Volume: Shipping Method:

Component Description: V PEB Main Circuit Board Part Number: 140301-N0402-63 Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life: Production Year:

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 

Mark-up 

Rate

Total 

Mark-up 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

.

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

.

1 . V Main Circuit Board Testing 180703-N0402-63 1

Functional Test, High Content 

Board 250-500 Chips/side and a 

Max of 70 odd form components.

T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly EOL Func.Test, High Content 206 2 2 1 0.809 $0.00 $29.83 $42.27 $84.54 $0.00 $0.29 $0.41 $0.70 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.70 $0.70

2 . V Main Circuit Board w-Conformal Coating 180703-N0402-64 1 PVA Coating Applicator T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Conformal Coat, UV Cure 250 1 1 1 0.809 $0.00 $29.83 $28.33 $28.33 $0.00 $0.12 $0.11 $0.23 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.23 $0.23

3 . V Main Circuit Board w-thru holes mnted 180703-N0402-65 1

Thru Hole Chip Placement T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Thru Hole, Manual 144 1 1 1 0.809 $0.00 $29.83 $23.00 $23.00 $0.00 $0.21 $0.16 $0.37 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.37 $0.37

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Series Gasoline Hybrid

MARK-UP COSTS TOTAL COSTS

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)

3 . V Main Circuit Board w-thru holes mnted 180703-N0402-65 1

Thru Hole Chip Placement 

Assembly Line, Manual Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Thru Hole, Manual 144 1 1 1 0.809 $0.00 $29.83 $23.00 $23.00 $0.00 $0.21 $0.16 $0.37 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.37 $0.37

4 . V Main Circuit Board w-SMT mnted 180703-N0402-66 1 DEK Screen Printer T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly SMT, High Content 138 2 1 2 0.809 $0.00 $29.83 $309.98 $619.96 $0.00 $0.43 $4.48 $4.91 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $4.91 $4.91

. .

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 . V Main Circuit Board FR4 180703-N0402-67 1 Commodity Pricing S $0.00 $8.75 $0.00 $8.75

2 . IC - Memory - Surface Mount 180703-N0402-68 1 Commodity Pricing S $0.00 $0.28 $0.00 $0.28

3 . IC - Surface Mount 180703-N0402-69 1 Commodity Pricing S $0.00 $1.15 $0.00 $1.15

4 . MOSFET - Surface Mount 180703-N0402-70 1 Commodity Pricing S $0.00 $1.03 $0.00 $1.03

5 . Schottky Diode - Surface Mount 180703-N0402-71 1 Commodity Pricing S $0.00 $0.28 $0.00 $0.28

6 . Resistors 180703-N0402-72 220 Commodity Pricing S $0.00 $0.01 $0.00 $2.20

7 . Capacitors 180703-N0402-73 114 Commodity Pricing S $0.00 $0.01 $0.00 $1.14

8 . LEM Current Sensor 180703-N0402-74 4 Commodity Pricing S $0.00 $2.25 $0.00 $9.00

9 . MOSFET - Surface Mount 180703-N0402-75 2 Commodity Pricing S $0.00 $0.49 $0.00 $0.98

10 . IC - Surface Mount 180703-N0402-76 1 Commodity Pricing S $0.00 $15.74 $0.00 $15.74

11 . IC - Analog to Digital Converter - Surface Mount 180703-N0402-77 1 Commodity Pricing S $0.00 $3.50 $0.00 $3.50

12 . IC - Choke - Surface Mount 180703-N0402-78 2 Commodity Pricing S $0.00 $0.30 $0.00 $0.60

13 . IC 180703-N0402-79 1 Commodity Pricing S $0.00 $24.09 $0.00 $24.09

14 . IC - Memory - Surface Mount 180703-N0402-80 1 Commodity Pricing S $0.00 $0.28 $0.00 $0.28

15 . IC - Surface Mount 180703-N0402-81 1 Commodity Pricing S $0.00 $1.03 $0.00 $1.03

16 . IC - Voltage Regulart - Surface Mount 180703-N0402-82 1 Commodity Pricing S $0.00 $0.71 $0.00 $0.71

17 . IC - Amplifier - Surface Mount 180703-N0402-83 3 Commodity Pricing S $0.00 $0.24 $0.00 $0.72

18 . Schottky Diode - Surface Mount 180703-N0402-84 2 Commodity Pricing S $0.00 $0.54 $0.00 $1.08

19 . MOSFET - Surface Mount 180703-N0402-85 1 Commodity Pricing S $0.00 $0.36 $0.00 $0.36

20 . Schottky Diode - Surface Mount 180703-N0402-86 4 Commodity Pricing S $0.00 $0.29 $0.00 $1.16

21 . Diode - Surface Mount 180703-N0402-87 3 Commodity Pricing S $0.00 $0.19 $0.00 $0.57

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or 

OEM for Final or Sub-Assembly. In addition component material cost is accounted for in 

T1 quote sheet. Thus component cost will only be included for Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier 

for Subassembly.

21

22 . IC - Surface Mount 180703-N0402-88 1 Commodity Pricing S $0.00 $0.33 $0.00 $0.33

23 . Schottky Diode - Surface Mount 180703-N0402-89 4 Commodity Pricing S $0.00 $0.11 $0.00 $0.44

24 . IC - Surface Mount 180703-N0402-90 1 Commodity Pricing S $0.00 $0.60 $0.00 $0.60

25 . Schottky - Diode - Surface Mount 180703-N0402-91 3 Commodity Pricing S $0.00 $0.28 $0.00 $0.84

26 . Schottky - Diode - Surface Mount 180703-N0402-92 22 Commodity Pricing S $0.00 $0.08 $0.00 $1.76

27 . V Capacitors 180703-N0402-93 88 Commodity Pricing S $0.00 $0.01 $0.00 $0.88

28 . V Resistors 180703-N0402-94 106 Commodity Pricing S $0.00 $0.01 $0.00 $1.06

29 . Inductor 513-1489-1-ND 180703-N0402-95 2 Commodity Pricing S $0.00 $0.66 $0.00 $1.32

30 . Inductor SRR1208-471KLTR-ND 180703-N0402-96 2 Commodity Pricing S $0.00 $0.36 $0.00 $0.72

31 . Aluminum Capacitor 493-2289-1-ND 180703-N0402-97 4 Commodity Pricing S $0.00 $0.38 $0.00 $1.52

32 . Aluminum Capacitor AFK686M2AH32T-F-ND 180703-N0402-98 4 Commodity Pricing S $0.00 $1.02 $0.00 $4.08

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

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

Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 High Assembly Complexity

System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid) Annual Component Volume: Shipping Method:

Component Description: V PEB Main Circuit Board Part Number: 140301-N0402-63 Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life: Production Year:

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 

Mark-up 

Rate

Total 

Mark-up 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Series Gasoline Hybrid

MARK-UP COSTS TOTAL COSTS

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)

33 . Aluminum Capacitor AFK477M35H32T-F-ND 180703-N0402-99 2 Commodity Pricing S $0.00 $0.97 $0.00 $1.94

34 . Aluminum Capacitor PCE4439TR-ND 180703-N0402-100 1 Commodity Pricing S $0.00 $0.22 $0.00 $0.22

35 . Aluminum Capacitor PCE4442TR-ND 180703-N0402-101 1 Commodity Pricing S $0.00 $0.22 $0.00 $0.22

36 . Aluminum Capacitor AFK336M50X16T-F-ND 180703-N0402-102 1 Commodity Pricing S $0.00 $0.53 $0.00 $0.53

37 . Voltage Regulator LM1085ISX-3.3-ND 180703-N0402-103 1 Commodity Pricing S $0.00 $1.20 $0.00 $1.20

38 . IC - CRYSTAL 631-1011-6-ND-1 180703-N0402-104 1 Commodity Pricing S $0.00 $0.31 $0.00 $0.31

39 . Zener Diode SMBJ5345B-TPMSTR-ND 180703-N0402-105 1 Commodity Pricing S $0.00 $0.01 $0.00 $0.01

40 . Inductor M8723-ND 180703-N0402-106 1 Commodity Pricing S $0.00 $3.75 $0.00 $3.75

41 . V Power Transformer 180703-N0402-107 1 Commodity Pricing S $0.00 $1.75 $0.00 $1.75

42 . V Flexible Connector V Flexible Connector 180703-N0402-108 180703-N0402-108 8 Commodity Pricing Commodity Pricing S $0.00 $0.35 $0.00 $2.80

43 . Connector 12092320 180703-N0402-109 2 Commodity Pricing S $0.00 $7.04 $0.00 $14.08

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $121.22

T1 or OEM Total Manufacturing Cost: $115.01 $1.05 $5.16 $121.22 $0.00 $0.00 $0.00 $0.00 $0.00 $121.22

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.85 $8.49 $9.70 $4.85 $23.88

Base Cost Impact to Vehicle: $115.01 $1.05 $5.16 $121.22 $0.85 $8.49 $9.70 $4.85 $23.88 $145.10

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $145.10

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 In-transit

Inventory Requirements (Weeks)

Supplier, Customer and In-transit

Inventory Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 2,250,000 60 5.00% $0 58 1000 6 57447

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

3

1

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

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

Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 High Assembly Complexity

System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid) Annual Component Volume: Shipping Method:

Component Description: V PEB Main Circuit Board Part Number: 140301-N0402-63 Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life: Production Year:

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 

Mark-up 

Rate

Total 

Mark-up 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Series Gasoline Hybrid

MARK-UP COSTS TOTAL COSTS

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)

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

.

. V Main Circuit Board Testing 180703-N0402-63

. V Main Circuit Board w-Conformal Coating 180703-N0402-64

. V Main Circuit Board w-thru holes mnted 180703-N0402-65

GENERAL COMPONENT INFORMATION

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

T1 High Assembly Complexity

Tooling Assumptions "x1000 "

Investment Assumptions "x1000 "

Material Labor Burden

Total Mfg'ing Cost (Component/

Assembly)

End Item 

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

Total Markup Cost (Component/

Assembly)

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

ek

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."

$0.00 $0.29 $0.41 $0.70 $0.00 $0.00 $0.00 $0.00 $0.00 Functional Test, High Content Board 250-500 Chips/side and a Max of 70 odd form components. 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.00 $0.12 $0.11 $0.23 $0.00 $0.00 $0.00 $0.00 $0.00 PVA Coating Applicator 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.00 $0.21 $0.16 $0.37 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 96 37.60 85% 113 31.96

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information

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

TOOLING & INVESTMENT

. V Main Circuit Board w-thru holes mnted 180703-N0402-65

. V Main Circuit Board w-SMT mnted 180703-N0402-66

.

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

.

. V Main Circuit Board FR4 180703-N0402-67

. IC - Memory - Surface Mount 180703-N0402-68

. IC - Surface Mount 180703-N0402-69

. MOSFET - Surface Mount 180703-N0402-70

. Schottky Diode - Surface Mount 180703-N0402-71

. Resistors 180703-N0402-72

. Capacitors 180703-N0402-73

. LEM Current Sensor 180703-N0402-74

. MOSFET - Surface Mount 180703-N0402-75

. IC - Surface Mount 180703-N0402-76

. IC - Analog to Digital Converter - Surface Mount 180703-N0402-77

. IC - Choke - Surface Mount 180703-N0402-78

. IC 180703-N0402-79

. IC - Memory - Surface Mount 180703-N0402-80

. IC - Surface Mount 180703-N0402-81

. IC - Voltage Regulart - Surface Mount 180703-N0402-82

. IC - Amplifier - Surface Mount 180703-N0402-83

. Schottky Diode - Surface Mount 180703-N0402-84

. MOSFET - Surface Mount 180703-N0402-85

. Schottky Diode - Surface Mount 180703-N0402-86

. Diode - Surface Mount 180703-N0402-87

$0.00 $0.21 $0.16 $0.37 $0.00 $0.00 $0.00 $0.00 $0.00 Thru Hole Chip Placement Assembly Line, Manual Assembly 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$0.00 $0.43 $4.48 $4.91 $0.00 $0.00 $0.00 $0.00 $0.00 Separate dedicated stations for Top and Bottom Side component mounting to maximize efficiency / capacity 5 2 10 100 47 4700 96 37.60 85% 113 31.96

$8.75 $8.75

$0.28 $0.28

$1.15 $1.15

$1.03 $1.03

$0.28 $0.28

$2.20 $2.20

$1.14 $1.14

$9.00 $9.00

$0.98 $0.98

$15.74 $15.74

$3.50 $3.50

$0.60 $0.60

$24.09 $24.09

$0.28 $0.28

$1.03 $1.03

$0.71 $0.71

$0.72 $0.72

$1.08 $1.08

$0.36 $0.36

$1.16 $1.16

$0.57 $0.57

. IC - Surface Mount 180703-N0402-88

. Schottky Diode - Surface Mount 180703-N0402-89

. IC - Surface Mount 180703-N0402-90

. Schottky - Diode - Surface Mount 180703-N0402-91

. Schottky - Diode - Surface Mount 180703-N0402-92

. V Capacitors 180703-N0402-93

. V Resistors 180703-N0402-94

. Inductor 513-1489-1-ND 180703-N0402-95

. Inductor SRR1208-471KLTR-ND 180703-N0402-96

. Aluminum Capacitor 493-2289-1-ND 180703-N0402-97

. Aluminum Capacitor AFK686M2AH32T-F-ND 180703-N0402-98

$0.33 $0.33

$0.44 $0.44

$0.60 $0.60

$0.84 $0.84

$1.76 $1.76

$0.88 $0.88

$1.06 $1.06

$1.32 $1.32

$0.72 $0.72

$1.52 $1.52

$4.08 $4.08

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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.

. Aluminum Capacitor AFK477M35H32T-F-ND 180703-N0402-99

. Aluminum Capacitor PCE4439TR-ND 180703-N0402-100

. Aluminum Capacitor PCE4442TR-ND 180703-N0402-101

. Aluminum Capacitor AFK336M50X16T-F-ND 180703-N0402-102

. Voltage Regulator LM1085ISX-3.3-ND 180703-N0402-103

. IC - CRYSTAL 631-1011-6-ND-1 180703-N0402-104

. Zener Diode SMBJ5345B-TPMSTR-ND 180703-N0402-105

. Inductor M8723-ND 180703-N0402-106

. V Power Transformer 180703-N0402-107

. V Flexible Connector 180703-N0402-108

T1 High Assembly Complexity

Tooling Assumptions "x1000 "

Investment Assumptions "x1000 "

Material Labor Burden

Total Mfg'ing Cost (Component/

Assembly)

End Item 

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

Total Markup Cost (Component/

Assembly)

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

ek

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."

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information

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

TOOLING & INVESTMENT

$1.94 $1.94

$0.22 $0.22

$0.22 $0.22

$0.53 $0.53

$1.20 $1.20

$0.31 $0.31

$0.01 $0.01

$3.75 $3.75

$1.75 $1.75

. V Flexible Connector 180703-N0402-108 $2.80 $2.80

. Connector 12092320 180703-N0402-109

$2.80 $2.80

$14.08 $14.08

Material Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$115.01 $1.05 $5.16 $121.22 $0.00 $0.00 $0.00 $0.00 $0.00

$121.22

$0 $0

2

Notes: 

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

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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.

T1 High Assembly Complexity

Tooling Assumptions "x1000 "

Investment Assumptions "x1000 "

Material Labor Burden

Total Mfg'ing Cost (Component/

Assembly)

End Item 

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

Total Markup Cost (Component/

Assembly)

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

ek

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."

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information

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

TOOLING & INVESTMENT

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

.

. V Main Circuit Board Testing 180703-N0402-63

. V Main Circuit Board w-Conformal Coating 180703-N0402-64

. V Main Circuit Board w-thru holes mnted 180703-N0402-65

GENERAL COMPONENT INFORMATION

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

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

Resulting Pieces/Hour

Resulting Cycle Time/ Part

"Sec.

Total Number of Direct Operators

 35 1 1 35 1.0 2.0 206 17.50 2.00

 14 1 1 14 1.0 1.0 250 14.40 1.00

 25 1 1 25 1.0 1.0 144 25.00 1.00

Project Process Requirement

. V Main Circuit Board w-thru holes mnted 180703-N0402-65

. V Main Circuit Board w-SMT mnted 180703-N0402-66

.

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

.

. V Main Circuit Board FR4 180703-N0402-67

. IC - Memory - Surface Mount 180703-N0402-68

. IC - Surface Mount 180703-N0402-69

. MOSFET - Surface Mount 180703-N0402-70

. Schottky Diode - Surface Mount 180703-N0402-71

. Resistors 180703-N0402-72

. Capacitors 180703-N0402-73

. LEM Current Sensor 180703-N0402-74

. MOSFET - Surface Mount 180703-N0402-75

. IC - Surface Mount 180703-N0402-76

. IC - Analog to Digital Converter - Surface Mount 180703-N0402-77

. IC - Choke - Surface Mount 180703-N0402-78

. IC 180703-N0402-79

. IC - Memory - Surface Mount 180703-N0402-80

. IC - Surface Mount 180703-N0402-81

. IC - Voltage Regulart - Surface Mount 180703-N0402-82

. IC - Amplifier - Surface Mount 180703-N0402-83

. Schottky Diode - Surface Mount 180703-N0402-84

. MOSFET - Surface Mount 180703-N0402-85

. Schottky Diode - Surface Mount 180703-N0402-86

. Diode - Surface Mount 180703-N0402-87

 25 1 1 25 1.0 1.0 144 25.00 1.00

 42 2 1 26 2.0 1.0 138 26.00 2.00

. IC - Surface Mount 180703-N0402-88

. Schottky Diode - Surface Mount 180703-N0402-89

. IC - Surface Mount 180703-N0402-90

. Schottky - Diode - Surface Mount 180703-N0402-91

. Schottky - Diode - Surface Mount 180703-N0402-92

. V Capacitors 180703-N0402-93

. V Resistors 180703-N0402-94

. Inductor 513-1489-1-ND 180703-N0402-95

. Inductor SRR1208-471KLTR-ND 180703-N0402-96

. Aluminum Capacitor 493-2289-1-ND 180703-N0402-97

. Aluminum Capacitor AFK686M2AH32T-F-ND 180703-N0402-98

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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.

. Aluminum Capacitor AFK477M35H32T-F-ND 180703-N0402-99

. Aluminum Capacitor PCE4439TR-ND 180703-N0402-100

. Aluminum Capacitor PCE4442TR-ND 180703-N0402-101

. Aluminum Capacitor AFK336M50X16T-F-ND 180703-N0402-102

. Voltage Regulator LM1085ISX-3.3-ND 180703-N0402-103

. IC - CRYSTAL 631-1011-6-ND-1 180703-N0402-104

. Zener Diode SMBJ5345B-TPMSTR-ND 180703-N0402-105

. Inductor M8723-ND 180703-N0402-106

. V Power Transformer 180703-N0402-107

. V Flexible Connector 180703-N0402-108

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

Resulting Pieces/Hour

Resulting Cycle Time/ Part

"Sec.

Total Number of Direct Operators

Project Process Requirement

. V Flexible Connector 180703-N0402-108

. Connector 12092320 180703-N0402-109

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 9 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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.

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

Resulting Pieces/Hour

Resulting Cycle Time/ Part

"Sec.

Total Number of Direct Operators

Project Process Requirement

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 6 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

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

Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 High Assembly Complexity

System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid) Annual Component Volume: Shipping Method:

Component Description: V PEB Connector Module 8 Pin Part Number: 180701-N0202-110 Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life: Production Year:

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 

Mark-up 

Rate

Total 

Mark-up 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

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

.

1 . V PEB Connector Module 8 Pin w-stitching (w/Cover) 180703-N0402-110 1 assembled housing, conn, PCB, w/cover T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, LC 138 3 1 3 0.000 $0.00 $29.83 $100.00 $300.00 $0.00 $0.65 $2.17 $2.81 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.81 $2.81

2 . V PEB Conn Mod 8 Pin w-PCB mnted - wire stitch bonded 180703-N0402-111 1 assembled housing, conn, PCB, stitched T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, LC 360 1 1 1 0.000 $0.00 $29.83 $100.00 $100.00 $0.00 $0.08 $0.28 $0.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.36 $0.36

3 . V PEB Conn Mod 8 Pin w-PCB mnted 180703-N0402-112 1 assembled housing, conn, PCB T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, LC 129 2 1 3 0.000 $0.00 $29.83 $100.00 $300.00 $0.00 $0.46 $2.33 $2.80 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.80 $2.80

4 . V PEB Conn Mod 8 Pin, Housing Assy (w/Connector Header) 180702-N0402-01 1 assembled w/conn header, seals, etc. T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Elec. Assembly, LC 180 3 1 3 0.000 $0.00 $29.83 $100.00 $300.00 $0.00 $0.50 $1.67 $2.16 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.16 $2.16

5 . V PEB Conn Mod 8 Pin, Housing Assy (Washed) 180702-N0402-02 1 Turbo Tunnel T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Work Cell Operator-OEM Washing Equipment, LMC 327 1 1 1 0.000 $0.00 $95.87 $20.81 $20.81 $0.00 $0.29 $0.06 $0.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.36 $0.36

6 . V PEB Con Mod 8 Pin, Hsg Machined 180702-N0402-03 1

EC-300 - Pallet Size 300 mm square, 550 

lb Capacity T1 Assembly, Mark-up Applied @ Bottom. Not Applicable CNC Operator CNC Machining, LC, Automatic Load 120 4 4 1 0.000 $0.00 $36.98 $40.26 $161.04 $0.00 $1.23 $1.34 $2.57 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $2.57 $2.57

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Series Gasoline Hybrid

MARK-UP COSTS TOTAL COSTS

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)

lb Capacity

7 . V PEB Con Mod 8 Pin, Hsg - Heat Treat 180702-N0402-04 1 Heat Treat T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Heat Treat Operator Heat Treat, SMS, LMC 205 0.25 1 1 0.000 $0.00 $47.72 $50.00 $50.00 $0.00 $0.06 $0.24 $0.30 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.30 $0.30

8 . V PEB Connector Module 8 Pin, Housing Cast-Material 180702-N0402-05 1

Cold Chamber Die Casting Machine (1000-

1800 Ton) T1 Assembly, Mark-up Applied @ Bottom. Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, MS 511 1 1 1 0.599 $1.10 $41.48 $197.05 $197.05 $0.66 $0.08 $0.39 $1.13 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.13 $1.13

9 . V PEB Connector Module 8 Pin, PCB Assy 180703-N0402-113 1

Functional Test, Low Content Boards with 

0-160 Chips/side and a Max of 70 odd form 

components.

T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly EOL Func.Test, Low Content 120 2 1 2 0.000 $0.00 $29.83 $14.09 $28.18 $0.00 $0.50 $0.23 $0.73 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.73 $0.73

10 . V PEB Con Mod 8 Pin, PCB Depaneled 180703-N0402-114 1

De-Panel-Router Station, In-Line, 

Complex geometries an/or vibration 

sensitive boards/inverta delta boards.

T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly De-Panel, In-Line, Router 360 1 1 1 0.000 $0.00 $29.83 $24.38 $24.38 $0.00 $0.08 $0.07 $0.15 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.15 $0.15

11 . V PEB Con Mod 8 Pin, PCB Conformal Coated 180703-N0402-115 1 PVA Coating Applicator T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Plating/Coating Operator Conformal Coat, UV Cure 327 1 1 1 0.000 $0.00 $40.84 $28.33 $28.33 $0.00 $0.12 $0.09 $0.21 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.21 $0.21

12 . V PEB Con Mod 8 Pin, PCB w thru hole parts 180703-N0402-116 1

Thru Hole Chip Placement Assembly Line, 

1-Automated and 1 Manual workstation, 

Max 9 chips per side with automated 

equipment.

T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly Thru Hole, Auto 240 1 1 1 0.000 $0.00 $29.83 $62.59 $62.59 $0.00 $0.12 $0.26 $0.39 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.39 $0.39

13 . V PEB Con Mod 8 Pin, PCB w SMT parts 180703-N0402-117 1 DEK Screen Printer T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Electrical Assembly SMT, Low Content 277 0.5 1 1 0.000 $0.00 $29.83 $212.63 $212.63 $0.00 $0.05 $0.77 $0.82 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.82 $0.82

14 . V Cover, PEB 8 pin Module-Stamping 180703-N0402-118 1 Turbo Tunnel T1 Assembly, Mark-up Applied @ Bottom. Not Applicable Work Cell Assembly Washing Equipment, LMC 7200 1 1 2 0.000 $0.00 $39.23 $20.81 $41.62 $0.00 $0.01 $0.01 $0.01 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.01 $0.01

15 . V Cover, PEB 8 pin Module-Blank 180703-N0402-119 1 Vertical Stamping Press, Tonnage 60-200 T1 Assembly, Mark-up Applied @ Bottom. LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, XSS 900 0.5 1 1 0.430 $0.45 $42.73 $24.60 $24.60 $0.19 $0.02 $0.03 $0.24 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.24 $0.24

.

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 . V Seal PEB Connector 180703-N0402-120 1 Commodity Pricing S $0.00 $0.07 $0.00 $0.07

2 . V PEB 8 pin Connector Header 180703-N0402-121 1 Commodity Pricing S $0.00 $0.91 $0.00 $0.91

3 . V Bolt 8 Pin Connector Housing 180702-N0402-06 2 Commodity Pricing S $0.00 $0.02 $0.00 $0.04

4 . V Vent Cap PEB 8 pin Module 180703-N0402-122 1 Commodity Pricing S $0.00 $0.20 $0.00 $0.20

5 . V PEB Con Mod 8 Pin, PCB bare board 180703-N0402-123 1 Commodity Pricing S $0.00 $1.78 $0.00 $1.78

6 . V Resistors - Caps 180703-N0402-124 87 Commodity Pricing S $0.00 $0.01 $0.00 $0.87

7 . V Transistors 180703-N0402-125 3 Commodity Pricing S $0.00 $0.03 $0.00 $0.09

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub-Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM 

for Final or Sub-Assembly. In addition component material cost is accounted for in T1 quote 

sheet. Thus component cost will only be included for Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for 7 . V Transistors 180703-N0402-125 3 Commodity Pricing S $0.00 $0.03 $0.00 $0.09

8 . V Capacitor - odd form 180703-N0402-126 1 Commodity Pricing S $0.00 $0.03 $0.00 $0.03

9 . V Capacitor 5PW 33 50V 180703-N0402-127 1 Commodity Pricing S $0.00 $0.35 $0.00 $0.35

10 . V Seal PEB Cover 180785-N0402-05 1 Commodity Pricing S $0.00 $0.11 $0.00 $0.11

11 . V Bolt PEB Module Cover 180780-N0402-46 6 Commodity Pricing S $0.00 $0.02 $0.00 $0.12

12 . V Bolt 8 pin PEB PCB to housing 180780-N0402-47 7 Commodity Pricing S $0.00 $0.02 $0.00 $0.14

13 . V Inductor Asm, Coil, Large 180703-N0402-128 1 Commodity Pricing S $0.00 $1.50 $0.00 $1.50

14 . V Integrated Circuit #1 IC1 335H 180703-N0402-129 1 Commodity Pricing S $0.00 $0.04 $0.00 $0.04

15 . V Integrated Circuit #2 IC2 5611T65K CD4093MQ 180703-N0402-130 1 Commodity Pricing S $0.00 $0.09 $0.00 $0.09

16 . V Integrated Circuit #3 IC3 1431Q1 180703-N0402-131 1 Commodity Pricing S $0.00 $1.06 $0.00 $1.06

17 . V Integrated Circuit #4 IC4 277 21 543 180703-N0402-132 1 Commodity Pricing S $0.00 $0.24 $0.00 $0.24

18 . V Integrated Circuit #5 IC5 842 21 528 180703-N0402-133 1 Commodity Pricing S $0.00 $0.28 $0.00 $0.28

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for 

Subassembly.

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 6 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

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

Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 High Assembly Complexity

System Description: Saturn Vue, Mild Hybrid (aka Start-Stop Hybrid) Annual Component Volume: Shipping Method:

Component Description: V PEB Connector Module 8 Pin Part Number: 180701-N0202-110 Weekly Component Volume: Packaging Specification:

Component Quote Level: Estimated Product Life: Production Year:

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 

Mark-up 

Rate

Total 

Mark-up 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Series Gasoline Hybrid

MARK-UP COSTS TOTAL COSTS

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)

19 . V Integrated Circuit #6 IC6 NEC K3811 5XM 180703-N0402-134 1 Commodity Pricing S $0.00 $3.12 $0.00 $3.12

20 . V Integrated Circuit #7 IC7 0150 30SC4M 180703-N0402-135 1 Commodity Pricing S $0.00 $1.05 $0.00 $1.05

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $27.14

T1 or OEM Total Manufacturing Cost: $12.95 $4.27 $9.93 $27.14 $0.00 $0.00 $0.00 $0.00 $0.00 $27.14 3

1

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.19 $1.90 $2.17 $1.09 $5.35

Base Cost Impact to Vehicle: $12.95 $4.27 $9.93 $27.14 $0.19 $1.90 $2.17 $1.09 $5.35 $32.49

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $32.49

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 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 6 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

.

. V PEB Connector Module 8 Pin w-stitching (w/Cover) 180703-N0402-110

. V PEB Conn Mod 8 Pin w-PCB mnted - wire stitch bonded 180703-N0402-111

. V PEB Conn Mod 8 Pin w-PCB mnted 180703-N0402-112

. V PEB Conn Mod 8 Pin, Housing Assy (w/Connector Header) 180702-N0402-01

. V PEB Conn Mod 8 Pin, Housing Assy (Washed) 180702-N0402-02

. V PEB Con Mod 8 Pin, Hsg Machined 180702-N0402-03

GENERAL COMPONENT INFORMATION

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

T1 High Assembly Complexity

Tooling Assumptions "x1000 "

Investment Assumptions "x1000 "

Material Labor Burden

Total Mfg'ing Cost (Component/

Assembly)

End Item 

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

Total Markup Cost (Component/

Assembly)

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

ek

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

$0.00 $0.65 $2.17 $2.81 $0.00 $0.00 $0.00 $0.00 $0.00 assembled housing, conn, PCB, w/cover 5 2 10 100 47 4700 96 37.60 85% 113 31.96 60 3

$0.00 $0.08 $0.28 $0.36 $0.00 $0.00 $0.00 $0.00 $0.00 assembled housing, conn, PCB, stitched 5 2 10 100 47 4700 96 37.60 85% 113 31.96 10 1

$0.00 $0.46 $2.33 $2.80 $0.00 $0.00 $0.00 $0.00 $0.00 assembled housing, conn, PCB 5 2 10 100 47 4700 96 37.60 85% 113 31.96 50 3

$0.00 $0.50 $1.67 $2.16 $0.00 $0.00 $0.00 $0.00 $0.00 assembled w/conn header, seals, etc. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 54 3

$0.00 $0.29 $0.06 $0.36 $0.00 $0.00 $0.00 $0.00 $0.00 Load - Wash - Unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 1

$0.00 $1.23 $1.34 $2.57 $0.00 $0.00 $0.00 $0.00 $0.00 Finish Machining 5 2 10 100 47 4700 96 37.60 85% 113 31.96 120 1

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information

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

TOOLING & INVESTMENT

. V PEB Con Mod 8 Pin, Hsg - Heat Treat 180702-N0402-04

. V PEB Connector Module 8 Pin, Housing Cast-Material 180702-N0402-05

. V PEB Connector Module 8 Pin, PCB Assy 180703-N0402-113

. V PEB Con Mod 8 Pin, PCB Depaneled 180703-N0402-114

. V PEB Con Mod 8 Pin, PCB Conformal Coated 180703-N0402-115

. V PEB Con Mod 8 Pin, PCB w thru hole parts 180703-N0402-116

. V PEB Con Mod 8 Pin, PCB w SMT parts 180703-N0402-117

. V Cover, PEB 8 pin Module-Stamping 180703-N0402-118

. V Cover, PEB 8 pin Module-Blank 180703-N0402-119

.

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

.

. V Seal PEB Connector 180703-N0402-120

. V PEB 8 pin Connector Header 180703-N0402-121

. V Bolt 8 Pin Connector Housing 180702-N0402-06

. V Vent Cap PEB 8 pin Module 180703-N0402-122

. V PEB Con Mod 8 Pin, PCB bare board 180703-N0402-123

. V Resistors - Caps 180703-N0402-124

. V Transistors 180703-N0402-125

$0.00 $0.06 $0.24 $0.30 $0.00 $0.00 $0.00 $0.00 $0.00 See file titled "V PEB Assembly Heat Treat Cost Calcs" for batch size calculation 5 2 10 100 47 4700 96 37.60 85% 113 31.96 27,000 1

$0.66 $0.08 $0.39 $1.13 $0.00 $0.00 $0.00 $0.00 $0.00 Premium of 10% added to cycle time to account for post-cast trim operation 5 2 10 100 47 4700 96 37.60 85% 113 31.96 38 1

$0.00 $0.50 $0.23 $0.73 $0.00 $0.00 $0.00 $0.00 $0.00 Functional test 5 2 10 100 47 4700 96 37.60 85% 113 31.96 35 2

$0.00 $0.08 $0.07 $0.15 $0.00 $0.00 $0.00 $0.00 $0.00 Depanel and unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 10 1

$0.00 $0.12 $0.09 $0.21 $0.00 $0.00 $0.00 $0.00 $0.00 Apply conformal coat to PCB 5 2 10 100 47 4700 96 37.60 85% 113 31.96 11 1

$0.00 $0.12 $0.26 $0.39 $0.00 $0.00 $0.00 $0.00 $0.00 Mate PCB w/Coil Inductor Assy 5 2 10 100 47 4700 96 37.60 85% 113 31.96 15 1

$0.00 $0.05 $0.77 $0.82 $0.00 $0.00 $0.00 $0.00 $0.00 Mount top side components to PC board 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1

$0.00 $0.01 $0.01 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 Load - Wash - Unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 15 2

$0.19 $0.02 $0.03 $0.24 $0.00 $0.00 $0.00 $0.00 $0.00 Galvinized Steel - G60-ton 5 2 10 100 47 4700 96 37.60 85% 113 31.96 4 1

$0.07 $0.07

$0.91 $0.91

$0.04 $0.04

$0.20 $0.20

$1.78 $1.78

$0.87 $0.87

. V Transistors 180703-N0402-125 $0.09 $0.09

. V Capacitor - odd form 180703-N0402-126

. V Capacitor 5PW 33 50V 180703-N0402-127

. V Seal PEB Cover 180785-N0402-05

. V Bolt PEB Module Cover 180780-N0402-46

. V Bolt 8 pin PEB PCB to housing 180780-N0402-47

. V Inductor Asm, Coil, Large 180703-N0402-128

. V Integrated Circuit #1 IC1 335H 180703-N0402-129

. V Integrated Circuit #2 IC2 5611T65K CD4093MQ 180703-N0402-130

. V Integrated Circuit #3 IC3 1431Q1 180703-N0402-131

. V Integrated Circuit #4 IC4 277 21 543 180703-N0402-132

. V Integrated Circuit #5 IC5 842 21 528 180703-N0402-133

$0.09 $0.09

$0.03 $0.03

$0.35 $0.35

$0.11 $0.11

$0.12 $0.12

$0.14 $0.14

$1.50 $1.50

$0.04 $0.04

$0.09 $0.09

$1.06 $1.06

$0.24 $0.24

$0.28 $0.28

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 6 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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.

. V Integrated Circuit #6 IC6 NEC K3811 5XM 180703-N0402-134

. V Integrated Circuit #7 IC7 0150 30SC4M 180703-N0402-135

T1 High Assembly Complexity

Tooling Assumptions "x1000 "

Investment Assumptions "x1000 "

Material Labor Burden

Total Mfg'ing Cost (Component/

Assembly)

End Item 

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

Total Markup Cost (Component/

Assembly)

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

ek

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information

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

TOOLING & INVESTMENT

$3.12 $3.12

$1.05 $1.05

Material Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$12.95 $4.27 $9.93 $27.14 $0.00 $0.00 $0.00 $0.00 $0.00

$27.14

2

Notes: 

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

$0 $0

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 6 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

.

. V PEB Connector Module 8 Pin w-stitching (w/Cover) 180703-N0402-110

. V PEB Conn Mod 8 Pin w-PCB mnted - wire stitch bonded 180703-N0402-111

. V PEB Conn Mod 8 Pin w-PCB mnted 180703-N0402-112

. V PEB Conn Mod 8 Pin, Housing Assy (w/Connector Header) 180702-N0402-01

. V PEB Conn Mod 8 Pin, Housing Assy (Washed) 180702-N0402-02

. V PEB Con Mod 8 Pin, Hsg Machined 180702-N0402-03

GENERAL COMPONENT INFORMATION

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

Piece/Cycle/Machine

Tack Time/Machine/Cycle "Seconds"

Multiplier, If Required for Parallel

Processing (1=Nothing)

Number of Equivalent Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/ Part

"Sec.

Total Number of Direct Operators

 1 26 3.0 1.0 138 26.00 3.00

 1 10 1.0 1.0 360 10.00 1.00

 1 28 3.0 1.0 129 28.00 2.00

 1 20 3.0 1.0 180 20.00 3.00

 1 11 1.0 1.0 327 11.00 1.00

 1 120 1.0 4.0 120 30.00 4.00

Project Process Requirement

. V PEB Con Mod 8 Pin, Hsg - Heat Treat 180702-N0402-04

. V PEB Connector Module 8 Pin, Housing Cast-Material 180702-N0402-05

. V PEB Connector Module 8 Pin, PCB Assy 180703-N0402-113

. V PEB Con Mod 8 Pin, PCB Depaneled 180703-N0402-114

. V PEB Con Mod 8 Pin, PCB Conformal Coated 180703-N0402-115

. V PEB Con Mod 8 Pin, PCB w thru hole parts 180703-N0402-116

. V PEB Con Mod 8 Pin, PCB w SMT parts 180703-N0402-117

. V Cover, PEB 8 pin Module-Stamping 180703-N0402-118

. V Cover, PEB 8 pin Module-Blank 180703-N0402-119

.

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

.

. V Seal PEB Connector 180703-N0402-120

. V PEB 8 pin Connector Header 180703-N0402-121

. V Bolt 8 Pin Connector Housing 180702-N0402-06

. V Vent Cap PEB 8 pin Module 180703-N0402-122

. V PEB Con Mod 8 Pin, PCB bare board 180703-N0402-123

. V Resistors - Caps 180703-N0402-124

. V Transistors 180703-N0402-125

 1,540 27,000 1.0 1.0 205 17.53 0.25

 6 42 1.0 1.0 511 7.04 1.00

 1 30 2.0 1.0 120 30.00 2.00

 1 10 1.0 1.0 360 10.00 1.00

 1 11 1.0 1.0 327 11.00 1.00

 1 15 1.0 1.0 240 15.00 1.00

 1 13 1.0 1.0 277 13.00 0.50

 20 10 2.0 1.0 7200 0.50 1.00

 1 4 1.0 1.0 900 4.00 0.50

. V Transistors 180703-N0402-125

. V Capacitor - odd form 180703-N0402-126

. V Capacitor 5PW 33 50V 180703-N0402-127

. V Seal PEB Cover 180785-N0402-05

. V Bolt PEB Module Cover 180780-N0402-46

. V Bolt 8 pin PEB PCB to housing 180780-N0402-47

. V Inductor Asm, Coil, Large 180703-N0402-128

. V Integrated Circuit #1 IC1 335H 180703-N0402-129

. V Integrated Circuit #2 IC2 5611T65K CD4093MQ 180703-N0402-130

. V Integrated Circuit #3 IC3 1431Q1 180703-N0402-131

. V Integrated Circuit #4 IC4 277 21 543 180703-N0402-132

. V Integrated Circuit #5 IC5 842 21 528 180703-N0402-133

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 6 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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.

. V Integrated Circuit #6 IC6 NEC K3811 5XM 180703-N0402-134

. V Integrated Circuit #7 IC7 0150 30SC4M 180703-N0402-135

Piece/Cycle/Machine

Tack Time/Machine/Cycle "Seconds"

Multiplier, If Required for Parallel

Processing (1=Nothing)

Number of Equivalent Machines Required

Resulting Pieces/Hour

Resulting Cycle Time/ Part

"Sec.

Total Number of Direct Operators

Project Process Requirement

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 1 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 High Assembly Complexity

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Bracket, PEB Part Number: 180775-N0402-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

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 1 Assembly of PEB Bracket to SGCM/PEB 180701-N0402-01 & 180775-N0402-011

Subassembly of Assembly of 

Electonics Module to Bracket

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, MC, Base 164 1 1 1 0.000 $0.00 $38.55 $30.00 $30.00 $0.00 $0.24 $0.18 $0.42 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.42 $0.42 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

Costs Broken Out In

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

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 1A V Bracket, PEB 180775-N0402-001-10 1 Stamp T2/T3 Stamp/Form, MSMC LC-Steel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, LS 643 0.5 1 1 5.032 $0.45 $42.73 $141.76 $141.76 $2.26 $0.03 $0.22 $2.52 0.50% 6.50% 6.00% 1.00% 14.00% $0.35 $2.87 $2.87 $2.26

2 2A V Bracket, PEB 180775-N0402-001-9 1 Projection Weld T2/T3 Stamp/Form, MSMC Not Applicable Welding/Soldering Operator Mech Assembly, LMC, 

Base

2 2A V Bracket, PEB 180775-N0402-001-9 1 Projection Weld T2/T3 Stamp/Form, MSMC Not Applicable Welding/Soldering Operator 240 1 1 1 0.000 $0.00 $41.55 $22.50 $22.50 $0.00 $0.17 $0.09 $0.27 0.50% 6.50% 6.00% 1.00% 14.00% $0.04 $0.30 $0.30 $0.00

Base

240 1 1 1 0.000 $0.00 $41.55 $22.50 $22.50 $0.00 $0.17 $0.09 $0.27 0.50% 6.50% 6.00% 1.00% 14.00% $0.04 $0.30 $0.30 $0.00

3 3A V Bracket, PEB 180775-N0402-001-8 1 Projection Weld T2/T3 Plate/Finish Mech., 

SSLC Powder Coat Plating/Coating Operator Powder Coat, LC 180 1 1 1 0.000 $20.00 $40.84 $100.00 $100.00 $0.00 $0.23 $0.56 $0.78 0.30% 6.00% 4.00% 0.00% 10.30% $0.08 $0.86 $0.86 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 High Assembly Complexity

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Bracket, PEB Part Number: 180775-N0402-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

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

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 High Assembly Complexity

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Bracket, PEB Part Number: 180775-N0402-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

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

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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 1A V Bolt, PEB Bracket (PEB to Mount Bracket) 180780-N0402-003 7 S $0.00 $0.03 $0.00 $0.21 $0.21

2 0 $0.00 $0.00 $0.00 $0.00 $0.00

3 0 $0.00 $0.00 $0.00 $0.00 $0.00

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

5 0 $0.00 $0.00 $0.00 $0.00 $0.00

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

7 0 $0.00 $0.00 $0.00 $0.00 $0.00

8 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 8 0 $0.00 $0.00 $0.00 $0.00 $0.00

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$2.47

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $4.67

T1 or OEM Total Manufacturing Cost: $2.47 $0.67 $1.05 $4.20 $0.02 $0.23 $0.20 $0.03 $0.47 $4.67

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

3

1

Notes: T1 or OEM Total Manufacturing Cost: $2.47 $0.67 $1.05 $4.20 $0.02 $0.23 $0.20 $0.03 $0.47 $4.67

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.03 $0.33 $0.37 $0.19 $0.92

Base Cost Impact to Vehicle: $2.47 $0.67 $1.05 $4.20 $0.05 $0.55 $0.57 $0.21 $1.39 $5.59 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $5.59

Notes: 

a) Items 1,2, & 3 must a

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification: T1 High Assembly Complexity

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: V Bracket, PEB Part Number: 180775-N0402-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

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

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

1 Assembly of PEB Bracket to SGCM/PEB 180701-N0402-01 & 180775-N0402-01

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

$0.24 $0.18 $0.42 $0.00 $0.00 $0.00 $0.00 $0.00 Operator load/unload, multi-spindle autmaoted fastener feed and rundown. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 34 1 1 22 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

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

Purchase Part - High Impact Item (Full Cost Mapping)

1A V Bracket, PEB 180775-N0402-001-10

2A V Bracket, PEB 180775-N0402-001-9

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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

$0.03 $0.22 $2.52 $0.01 $0.16 $0.15 $0.03 $0.35 Progressive Die, Single Part/Hit 5 2 10 100 47 4700 96 37.60 85% 113 31.96 6 1 1 6 1.0 1.0

2A V Bracket, PEB 180775-N0402-001-9 $0.17 $0.09 $0.27 $0.00 $0.02 $0.02 $0.00 $0.04 Single Workcell, Oprator load/unload, auto nut placement and weld, 2 weldnuts per cycle. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 30 1 1 15 1.0 1.0

3A V Bracket, PEB 180775-N0402-001-8

$0.17 $0.09 $0.27 $0.00 $0.02 $0.02 $0.00 $0.04 Single Workcell, Oprator load/unload, auto nut placement and weld, 2 weldnuts per cycle. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 30 1 1 15 1.0 1.0

$0.23 $0.56 $0.78 $0.00 $0.05 $0.03 $0.00 $0.08 Powder Coat Line (Inlcudes prep, coat and cure), Conveyor line, operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 - 1 1 20 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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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

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

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

1A V Bolt, PEB Bracket (PEB to Mount Bracket) 180780-N0402-003

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

$0.21

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$0.67 $1.05 $4.20 $0.02 $0.23 $0.20 $0.03 $0.47

$4.67

2

Notes: 

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

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

1 Assembly of PEB Bracket to SGCM/PEB 180701-N0402-01 & 180775-N0402-01

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

164 22.00 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

1A V Bracket, PEB 180775-N0402-001-10

2A V Bracket, PEB 180775-N0402-001-9

#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! -

643 5.60 0.50

2A V Bracket, PEB 180775-N0402-001-9 240 15.00 1.00

3A V Bracket, PEB 180775-N0402-001-8

240 15.00 1.00

180 20.00 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! -

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

#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! -

#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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

1A V Bolt, PEB Bracket (PEB to Mount Bracket) 180780-N0402-003

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
$41.16 / 21' Pipe = $0.16 / inch

90 degree 5.02 " x $0.16 = $0.82

Straight 2.06 " x $0.16 = $0.34







Indented Bill of Materials

V PEB Assembly

LevelSymbol Name Description

. 0 V Bracket, PEB - Painted Final Part V Bracket, PEB - Painted Final Part

. 1 V Bracket, PEB - Washing V Bracket, PEB - Washing

. 2 V Bracket, PEB - Projection Welding V Bracket, PEB - Projection Welding

. 3 V Bracket-PEB Stamping V Bracket-PEB Stamping

. 4 V Bracket - PEB Stamped Material V Bracket - PEB Stamped Material

. 3 V Weld Nut - Projection PEB Bracket V Weld Nut - Projection PEB Bracket

. 0 V Bolt PEB Bracket V Bolt PEB Bracket

. 0 V PEB Module V PEB Module

. 1 V PEB Ground Strap Asm V PEB Ground Strap Asm

. 1 V Nut Ground to PEB V M6 Flange Nut

. 1 V Bolt PEB Connector Mod 8 Pin V Bolt M6x15 Hex and Philips w lock washer

. 1 V PEB Cold Plate Cover V PEB Cold Plate Cover

. 2 V PEB Cold Plate Cover Tube, Straight V PEB Cold Plate Cover Tube, Straight

. 3 V PEB Cold Plate Cover Tube, Straight-Tube Stock V PEB Cold Plate Cover Tube, Straight-Tube Stock

. 2 V PEB Cold Plate Cover Tube, 90 Degree V PEB Cold Plate Cover Tube, 90 Degree

. 3 V PEB Cold Plate Cover Tube, 90 Degree-Tube Stock V PEB Cold Plate Cover Tube, 90 Degree-Tube Stock

. 2 V PEB Cold Plate Cover V PEB Cold Plate Cover-Assembly

. 3 V PEB Cold Plate Cover V PEB Cold Plate Cover-Wash

. 4 V PEB Cold Plate Cover V PEB Cold Plate Cover-Machined

. 5 V PEB Cold Plate Cover V PEB Cold Plate Cover-Trim

. 6 V PEB Cold Plate Cover V PEB Cold Plate Cover-Die Cast

. 2 V PEB Cold Plate Cover Dowel Pin V PEB Cold Plate Cover Dowel Pin

. 1 V PEB Cold Plate Cover Bolt V Bolt M6x15 Hex and Philips w lock washer

. 1 V DC-DC Terminal Housing V DC-DC Terminal Housing

. 2 V DC-DC Terminal Housing V DC-DC Terminal Housing-Assembly

. 3 V DC-DC Terminal Housing V DC-DC Terminal Housing-Wash

. 4 V DC-DC Terminal Housing V DC-DC Terminal Housing-Machining

. 5 V DC-DC Terminal Housing V DC-DC Terminal Housing-Trim

. 6 V DC-DC Terminal Housing V DC-DC Terminal Housing-Die Cast

. 2 V Terminal Housing Vent Tube V Terminal Housing Vent Tube

. 1 Nut - DC / DC Terminal Cover V M6 Flange Nut

. 1 V PEB MG Terminal Housing V PEB MG Terminal Housing

. 2 V PEB MG Terminal Housing V PEB MG Terminal Housing-Assembly

. 3 V PEB MG Terminal Housing V PEB MG Terminal Housing-Cleaning

. 4 V PEB MG Terminal Housing V PEB MG Terminal Housing-Machining

. 5 V PEB MG Terminal Housing V PEB MG Terminal Housing-Trim
. 6 V PEB MG Terminal Housing V PEB MG Terminal Housing-Die Cast

. 2 V Terminal Housing Vent Tube V Terminal Housing Vent Tube

. 2 V PEB MG Terminal Housing Stud V PEB MG Terminal Housing Stud

. 1 Nut - PEB to MG Cable Terminal Cover V M6 Flange Nut

. 1 V PEB Sheet Metal Wrap Around Cover V PEB Sheet Metal Wrap Around Cover

. 2 V PEB Sheet Metal Wrap Around Cover V PEB Sheet Metal Wrap Around Cover-Stamping

. 1 Screw, PEB Sheet Metal Cover V Screw 4 mm Pan Hd Philips

. 1 V PEB Base Module V PEB Base Module

. 2 V PEB Lower Base Module V PEB Lower Base Module

. 3 V PEB Lower Base Module-W-wire bond V PEB Lower Base Module-W-wire bond

. 4 V PEB Lower Base Module-Pre stitching V PEB Lower Base Module-Pre stitching

. 5 V PEB Lower Base Module Housing Assy V PEB Lower Base Module Housing Assy

. 6 V PEB Lower Base Module Housing Assy Wash V PEB Lower Base Module Housing Assy Wash

. 7 V PEB Lower Base Module Housing Assy Machined V PEB Lower Base Module Housing Assy Machined

. 8 V PEB Lower Base Module Housing Assy Trim V PEB Lower Base Module Housing Assy Trim

. 9 V PEB Lower Base Module Housing Assy Cast Material V PEB Lower Base Module Housing Assy Cast Material

. 5 V Capacitor- Asm. V Capacitor- - Asm.

. 6 V Capacitor- - Blue V Capacitor- - Blue

. 6 V Capacitor- Housing V Capacitor- Housing

. 7 V Capacitor- Housing-Material V Capacitor- Housing-Material

. 5 V Inductor Coil - Small V Inductor Coil - Small

. 5 V Inductor Coil - Large V Inductor Coil - Large

. 5 V Inductor Cover - Small V Inductor Cover - Small

. 6 V Inductor Cover - Small V Inductor Cover - Small-Wash

. 7 V Inductor Cover - Small V Inductor Cover - Small-Material

. 5 V Inductor Cover- Large V Inductor Cover- Large

. 6 V Inductor Cover- Large V Inductor Cover- Large-Wash

. 7 V Inductor Cover- Large V Inductor Cover- Large-Material

. 5 V Bolt, Long, Small Board V Bolt, Long, Small Board

. 5 V Small Pad - Capacitor V Small Pad - Capacitor

. 6 V Small Pad - Capacitor-Material V Small Pad - Capacitor-Material

. 5 V Capacitor - Oval 63V V Capacitor - Oval 63V

. 5 V Large Pad - Capacitor V Large Pad - Capacitor

. 6 V Large Pad - Capacitor V Large Pad - Capacitor-Material

. 5 V Capacitor - Cylinder 80V V Capacitor - Cylinder 80V

. 5 V Capacitor - Square 75V V Capacitor - Square 75V

. 5 V Seal - Capacitor Cover V Seal - Capacitor Cover

. 5 V Capacitor Top Cover V Capacitor Top Cover

. 6 V Capacitor Top Cover V Capacitor Top Cover-Molded

. 7 V Capacitor Top Cover V Capacitor Top Cover-Molded-Material

. 6 V Anti-Crush Sleeve PEB mid housing V Anti-Crush Sleeve PEB mid housing

. 5 V Bolt, Long, Small Board V Bolt, Long, Small Board

. 5 V PEB Heat Transfer Plate A V PEB Heat Transfer Plate A

. 5 V PEB Heat Transfer Plate B V PEB Heat Transfer Plate B

. 5 V Bolt, Long, Small Board V Bolt, Long, Small Board

. 5 V PEB Lower Base Module Housing Assy V PEB Mid Base Module Housing Assy

. 6 V PEB Mid Base Module Housing Overmolded V PEB Mid Base Module Housing Overmolded
. 7 V PEB Mid Base Module Housing Raw Material V PEB Mid Base Module Housing Raw Material

. 7 V 5 Pin Terminal Set PEB Mid base Module Housing A V 5 Pin Terminal Set PEB Mid base Module Housing A

. 7 V Terminal Block PEB Coil Cavity V Terminal Block PEB Coil Cavity

. 8 V Terminal Block PEB Coil Cavity-Weld V Terminal Block PEB Coil Cavity-Weld

. 9 V Terminal Block PEB Coil Cavity-Wash V Terminal Block PEB Coil Cavity-Wash

. 10 V Terminal Block PEB Coil Cavity-Wash V Terminal Block PEB Coil Cavity-Stamp

. 8 V Terminal Nut press-weld V Terminal Nut press-weld

. 8 V Stud Terminal PEB V Stud Terminal PEB

. 7 V Terminal Block PEB - Fuse Connect - Coil Cavity V Terminal Block PEB - Fuse Connect - Coil Cavity

. 8 V Terminal Block PEB - Fuse Connect - Coil Cavit-W V Terminal Block PEB - Fuse Connect - Coil Cavit-W

. 9 V Terminal Block PEB - Fuse Connect - Coil Cavit-W V Terminal Block PEB - Fuse Connect - Coil Cavit-1

. 10 V Terminal Block PEB - Fuse Connect - Coil Cavit-S V Terminal Block PEB - Fuse Connect - Coil Cavit-S

. 8 V Stud Terminal PEB V Stud Terminal PEB

. 7 V Terminal Block PEB - Mtr/Alt Pass Through V Terminal Block PEB - Mtr/Alt Pass Through

. 8 V Terminal Block PEB - Mtr/Alt Pass Through-Weld V Terminal Block PEB - Mtr/Alt Pass Through-Weld

. 9 V Terminal Block PEB - Mtr/Alt Pass Through-Wash V Terminal Block PEB - Mtr/Alt Pass Through-Wash

. 10 V Terminal Block PEB - Mtr/Alt Pass Through-Stamp V Terminal Block PEB - Mtr/Alt Pass Through-Stamp

. 8 V Terminal Nut press-weld V Terminal Nut press-weld

. 8 V Stud Terminal PEB V Stud Terminal PEB

. 7 V Terminal PEB main to heat sink plate V Terminal PEB main to heat sink plate

. 8 V Terminal PEB main to heat sink plate-Wash V Terminal PEB main to heat sink plate-Wash

. 9 V Terminal PEB main to heat sink plate-Plate V Terminal PEB main to heat sink plate-Plate

. 10 V Terminal PEB main to heat sink plate-Stamp V Terminal PEB main to heat sink plate-Stamp

. 7 V Terminal Plate Capcitor Anode V Terminal Plate Capcitor Anode

. 8 V Terminal Plate Capcitor Anode-Stamp V Terminal Plate Capcitor Anode-Welding

. 9 V Terminal Plate Capcitor Anode-Wash V Terminal Plate Capcitor Anode-Wash

. 10 V Terminal Plate Capcitor Anode-Plate V Terminal Plate Capcitor Anode-Plate

. 11 V Terminal Plate Capcitor Anode-Stamp V Terminal Plate Capcitor Anode-Stamp

. 8 V Terminal Nut press-weld V Terminal Nut press-weld

. 7 V Terminal Plate Capcitor Cathode V Terminal Plate Capcitor Cathode

. 8 V Terminal Plate Capcitor Cathode-Weld V Terminal Plate Capcitor Cathode-Weld

. 9 V Terminal Plate Capcitor Cathode-Wash V Terminal Plate Capcitor Cathode-Wash

. 10 V Terminal Plate Capcitor Cathode-Plated V Terminal Plate Capcitor Cathode-Plated

. 11 V Terminal Plate Capcitor Cathode-Stamped V Terminal Plate Capcitor Cathode-Stamped

. 8 V Terminal Nut press-weld V Terminal Nut press-weld

. 6 V Threaded Insert steel PEB mid housing V Threaded Insert steel PEB mid housing

. 6 V Threaded Insert brass PEB mid housing V Threaded Insert brass PEB mid housing

. 6 V Anti-Crush Sleeve PEB mid housing V Anti-Crush Sleeve PEB mid housing

. 6 V Threaded Insert steel PEB mid housing V Threaded Insert steel PEB mid housing

. 5 V Large O-ring, Module V Large O-ring, Module

. 5 V Small O-ring, Module V Small O-ring, Module

. 5 V Bolt, Long, Small Board V Bolt, Long, Small Board

. 5 V Bolt , Long, Ciruit Boards V Bolt , Long, Ciruit Boards

. 2 V Copper Relay 5 V Copper Relay 5

. 3 V Copper Relay 5 Wash V Copper Relay 5 Wash

. 4 V Copper Relay 5 Plating V Copper Relay 5 Plating

. 5 V Copper Relay 5 Stamping V Copper Relay 5 Stamped
. 6 V Copper Relay 5 Material V Copper Relay 5 Material

. 3 V Copper Relay Insert V Copper Relay Insert

. 2 V Bolt, Long, Small Board V Bolt, Long, Small Board

. 2 V Bolt , Long, Ciruit Boards V Bolt , Long, Ciruit Boards

. 2 V Copper Relay 4 V Copper Relay 4

. 3 V Copper Relay 4 Wash V Copper Relay 4 Wash

. 4 V Copper Relay 4 Stamped V Copper Relay 4 Stamped

. 5 V Copper Relay 4 Stamped V Copper Relay 4 Material

. 3 V Copper Relay Insert V Copper Relay Insert

. 2 V Bolt, Long, Small Board V Bolt, Long, Small Board

. 2 V Copper Relay 3 V Copper Relay 3

. 3 V Copper Relay 3 Wash V Copper Relay 3 Wash

. 4 V Copper Relay 3 Stamped V Copper Relay 3 Stamped

. 5 V Copper Relay 3 Stamped V Copper Relay 3 Material

. 3 V Copper Relay Insert V Copper Relay Insert

. 2 V Bolt, Long, Small Board V Bolt, Long, Small Board

. 2 V Copper Relay 2 V Copper Relay 2

. 3 V Copper Relay 2 Wash V Copper Relay 2 Wash

. 4 V Copper Relay 2 Stamped V Copper Relay 2 Stamped

. 5 V Copper Relay 2 Stamped V Copper Relay 2 Material

. 3 V Relay Insert V Copper Relay Insert

. 2 V Bolt, Long, Small Board V Bolt, Long, Small Board

. 2 V Copper Relay 1 V Copper Relay 1

. 3 V Copper Relay 1 Stamped V Copper Relay 1 Stamped

. 4 V Copper Relay 1 Stamped V Copper Relay 1 Material

. 2 V Ground Cable V Ground Cable

. 2 V Bolt, Long, Small Board V Bolt, Long, Small Board

. 2 V Bolt , Long, Ciruit Boards V Bolt , Long, Ciruit Boards

. 2 V 175A Fuse V 175A Fuse

. 2 V Fuse Nut V Fuse Nut

. 2 V Main Circuit Board GD114438-2-3 V Main Circuit Board GD114438-2-3

. 3 V Main Circuit Board Testing V Main Circuit Board Testing

. 4 V Main Circuit Board Testing V Main Circuit Board w-Conformal Coating

. 5 V Main Circuit Board w-thru holes mnted V Main Circuit Board w-thru holes mnted

. 6 V Main Circuit Board w-SMT mnted V Main Circuit Board w-Auto thru hole mnted

. 7 V Main Circuit Board w-SMT mnted V Main Circuit Board w-SMT mnted

. 8 V Main Circuit Board FR4 V Main Circuit Board FR4

. 8 V Main Circuit Board BOTTOM SIDE - SURFACE MOUNT V Main Circuit Board BOTTOM SIDE - SURFACE MOUNT

. 9 IC - Memory - Surface Mount IC - Memory - Surface Mount

. 9 IC - Surface Mount IC - Surface Mount

. 9 MOSFET - Surface Mount MOSFET - Surface Mount

. 9 Schottky Diode - Surface Mount Schottky Diode - Surface Mount

. 9 Resistors Resistors

. 9 Capacitors Capacitors

. 8 V Main Circuit Board TOP SIDE - SURFACE MOUNT V Main Circuit Board TOP SIDE - SURFACE MOUNT

. 9 LEM Current Sensor LEM Current Sensor

. 9 MOSFET - Surface Mount MOSFET - Surface Mount
. 9 IC - Surface Mount IC - Surface Mount

. 9 IC - Analog to Digital Converter - Surface Mount IC - Analog to Digital Converter - Surface Mount

. 9 IC - Choke - Surface Mount IC - Choke - Surface Mount

. 9 IC IC

. 9 IC - Memory - Surface Mount IC - Memory - Surface Mount

. 9 IC - Surface Mount IC - Surface Mount

. 9 IC - Voltage Regulart - Surface Mount IC - Voltage Regulart - Surface Mount

. 9 IC - Amplifier - Surface Mount IC - Amplifier - Surface Mount

. 9 Schottky Diode - Surface Mount Schottky Diode - Surface Mount

. 9 MOSFET - Surface Mount MOSFET - Surface Mount

. 9 Schottky Diode - Surface Mount Schottky Diode - Surface Mount

. 9 Diode - Surface Mount Diode - Surface Mount

. 9 IC - Surface Mount IC - Surface Mount

. 9 Schottky Diode - Surface Mount Schottky Diode - Surface Mount

. 9 IC - Surface Mount IC - Surface Mount

. 9 Schottky - Diode - Surface Mount Schottky - Diode - Surface Mount

. 9 Schottky - Diode - Surface Mount Schottky - Diode - Surface Mount

. 9 Capacitors V Capacitors

. 9 Resistors V Resistors

. 8 "V Main Circuit Board TOP-SURFACE MOUNT, ODD FORM" "V Main Circuit Board TOP-SURFACE MOUNT, ODD FORM"

. 9 Inductor Inductor 513-1489-1-ND

. 9 Inductor Inductor SRR1208-471KLTR-ND

. 9 Aluminum Capacitor Aluminum Capacitor 493-2289-1-ND

. 9 Aluminum Capacitor Aluminum Capacitor AFK686M2AH32T-F-ND

. 9 Aluminum Capacitor Aluminum Capacitor AFK477M35H32T-F-ND

. 9 Aluminum Capacitor Aluminum Capacitor PCE4439TR-ND

. 9 Aluminum Capacitor Aluminum Capacitor PCE4442TR-ND

. 9 Aluminum Capacitor Aluminum Capacitor AFK336M50X16T-F-ND

. 9 LM1085 - Voltage Regulator Voltage Regulator LM1085ISX-3.3-ND

. 9 IC - CRYSTAL IC - CRYSTAL 631-1011-6-ND-1

. 9 Zener Diode Zener Diode SMBJ5345B-TPMSTR-ND

. 7 Inductor Inductor M8723-ND

. 7 Power Transformer V Power Transformer

. 7 Flexible Connector V Flexible Connector

. 6 Connector Connector 12092320

. 2 V Bolt, Short, Circuit Boards V Bolt, Short, Circuit Boards

. 2 V Small Circuit Board GD114438-1-2 V Small Circuit Board GD114438-1-2

. 3 V Small Circuit Board GD114438-1-2-Depannel V Small Circuit Board GD114438-1-2-Depannel

. 4 V Small Circuit Board GD114438-1-2-SMT V Small Circuit Board GD114438-1-2-SMT

. 4 V Capacitor - odd form V Capacitor - odd form

. 2 V Bolt, Short, Circuit Boards V Bolt, Short, Circuit Boards

. 2 V Bolt, Long, Small Board V Bolt, Long, Small Board

. 2 V Copper Relay Piece V Copper Relay Piece

. 3 V Copper Relay Piece-Wash V Copper Relay Piece-Wash

. 4 V Copper Relay Piece-Stamping V Copper Relay Piece-Stamping

. 5 V Copper Relay Piece-Material V Copper Relay Piece-Material

. 3 V Relay Insert V Copper Relay Insert
.

2 V Bolt , Long, Ciruit Boards V Bolt , Long, Ciruit Boards

.

2 V Seal, PEB Cover V Seal, PEB Cover

.

2 V Cover PEB Unit V Cover PEB Unit

.

3 V Cover PEB Unit-washed V Cover PEB Unit-washed

.

4 V Cover PEB Unit-machined V Cover PEB Unit-machined

.

5 V Cover PEB Unit-Trimed V Cover PEB Unit-Trimed

.

6 V Cover PEB Unit-Cast V Cover PEB Unit-Cast

.

7 V Cover PEB Unit-Cast-Material V Cover PEB Unit-Cast-Material

.

3 V Vent Cap PEB 8 pin Module V Vent Cap PEB 8 pin Module

.

2 V Stud PEB Cover V Stud PEB Cover

.

2 V Bolt, Long, PEB Cover V Bolt, Long, PEB Cover

.

2 V bolt Short, PEB Cover V bolt Short, PEB Cover

Design Profit ®
Copyright 2005© Munro & Associates, Inc.
Number Material

Piece 

Cost 

(Each) Weight

1 Assembly 2.79 2.9850 lb 1 Washed $2.79 2.9850 lb 1 Weldment $2.79 2.9850 lb 1 Steel - 1018 $2.77 2.9850 lb 1 Steel - 1018 $2.77 2.9850 lb 2 Commodity Pricing $0.01 0 lb 7 Commodity Pricing $0.03 0.015 lb 1 Assembly $156.89 19.6735 lb 1 Commodity Pricing $0.25 0.077 lb 1 Commodity Pricing $0.02 0.009 lb 4 Commodity Pricing $0.02 0.012 lb 1 Assembly $2.45 0.7700 lb 1 Machined $0.13 0.0800 lb 1 Steel Tube $0.13 0.0800 lb 1 Machined Machined $0.29 0.1800 lb 1 Steel Tube $0.29 0.1800 lb 1 Assembly $0.58 0.5100 lb 1 Washed $0.58 0.5100 lb 1 Machined $0.58 0.5100 lb 1 Aluminum - 380 $0.58 0.5100 lb 1 Aluminum - 380 $0.58 0.5100 lb 2 Commodity Pricing $0.72 0 lb

10 Commodity Pricing $0.02 0.012 lb 1 Assembly $0.52 0.4216 lb 1 Assembly $0.51 0.4200 lb 1 Washed $0.51 0.4200 lb 1 Machined $0.51 0.4200 lb 1 Trimmed $0.51 0.4200 lb 1 Aluminum - 380 $0.51 0.4200 lb 1 EPDM $0.01 0.0016 lb 3 Commodity Pricing $0.02 0.009 lb 1 Assembly $0.59 0.4961 lb 1 Assembly $0.56 0.4850 lb 1 Cleaned $0.56 0.4850 lb 1 Machined $0.56 0.4850 lb 1 Trimmed $0.56 0.4850 lb
1 Aluminum - 380 $0.56 0.4850 lb

1 EPDM $0.01 0.0016 lb

1 Commodity Pricing $0.02 0.0095 lb

3 Commodity Pricing $0.02 0.009 lb

1 Machined $0.45 0.4550 lb

1 Galvinized Steel - G60 $0.45 0.4550 lb

11 Commodity Pricing $0.01 0.003 lb

1 Assembly $139.23 12.2131 lb

1 Assembly $21.93 9.2912 lb V PEB Lower Base Module

1 Wire Bond $21.93 9.2912 lb V PEB Lower Base Module

1 Stitching $21.93 9.2912 lb V PEB Lower Base Module

1 Assembly $3.76 3.2550 lb V PEB Lower Base Module

1 Washed $3.76 3.2550 lb V PEB Lower Base Module

1 Machined $3.76 3.2550 lb V PEB Lower Base Module

1 Trimmed $3.76 3.2550 lb V PEB Lower Base Module

1 A380 $3.76 3.2550 lb V PEB Lower Base Module

1 Commodity Pricing $0.11 0.0122 lb V PEB Lower Base Module

1 Commodity Pricing $0.10 0.006 lb V PEB Lower Base Module

1 PBT GF20 $0.01 0.0062 lb V PEB Lower Base Module

1 PBT GF20 $0.01 0.0062 lb V PEB Lower Base Module

1 Commodity Pricing $0.00 0.53 lb V PEB Lower Base Module

1 Commodity Pricing $0.00 1.055 lb V PEB Lower Base Module

1 Steel $0.01 0.0108 lb V PEB Lower Base Module

1 Steel $0.01 0.0108 lb V PEB Lower Base Module

1 Steel - 1008 $0.01 0.0108 lb V PEB Lower Base Module

1 Steel $0.04 0.0260 lb V PEB Lower Base Module V PEB Lower Base Module

1 Steel $0.04 0.0260 lb V PEB Lower Base Module

1 Steel - 1008 $0.04 0.0260 lb V PEB Lower Base Module

3 Commodity Pricing $0.02 0.0033 lb V PEB Lower Base Module

1 SBR $0.03 0.0178 lb V PEB Lower Base Module

1 SBR $0.03 0.0178 lb V PEB Lower Base Module

1 Commodity Pricing $0.00 0.2106 lb V PEB Lower Base Module

1 SBR $0.09 0.0699 lb V PEB Lower Base Module

1 SBR $0.09 0.0699 lb V PEB Lower Base Module

3 Commodity Pricing $0.00 0.3142 lb V PEB Lower Base Module

1 Commodity Pricing $5.30 0.1995 lb V PEB Lower Base Module

1 Commodity Pricing $0.07 0.0022 lb V PEB Lower Base Module

1 PPS GF40 $1.34 0.1766 lb V PEB Lower Base Module

1 PPS GF40 $1.27 0.1766 lb V PEB Lower Base Module

1 PPS GF40 $1.27 0.1766 lb V PEB Lower Base Module

7 Commodity Pricing $0.01 0 lb V PEB Lower Base Module

6 Commodity Pricing $0.02 0.0033 lb V PEB Lower Base Module

1 Assembly $0.00 0.0399 lb V PEB Lower Base Module

1 Assembly $0.00 0.2138 lb V PEB Lower Base Module

8 Commodity Pricing $0.02 0.0033 lb V PEB Lower Base Module

1 Assembly $10.52 2.4200 lb V PEB Lower Base Module

1 Molded $9.96 2.4200 lb V PEB Lower Base Module
1 PPS $8.11 1.2290 lb V PEB Lower Base Module 8 Commodity Pricing $0.10 0 lb V PEB Lower Base Module 2 Assembly $0.10 0.0630 lb V PEB Lower Base Module 2 Weldment $0.04 0.0500 lb V PEB Lower Base Module 2 Washed $0.04 0.0500 lb V PEB Lower Base Module 2 Steel - 1008 $0.04 0.0500 lb V PEB Lower Base Module 2 Commodity Pricing $0.02 0.003 lb V PEB Lower Base Module 2 Commodity Pricing $0.04 0.01 lb V PEB Lower Base Module 1 Assembly $0.06 0.0200 lb V PEB Lower Base Module 1 Weldment $0.02 0.0100 lb V PEB Lower Base Module 1 Washed $0.02 0.0100 lb V PEB Lower Base Module 1 Steel - 1008 $0.02 0.0100 lb V PEB Lower Base Module 1 Commodity Pricing $0.04 0.01 lb V PEB Lower Base Module 3 Assembly $0.10 0.0630 lb V PEB Lower Base Module 3 Weldment $0.04 0.0500 lb V PEB Lower Base Module 3 Washed $0.04 0.0500 lb V PEB Lower Base Module 3 Steel - 1008 $0.04 0.0500 lb V PEB Lower Base Module 3 Commodity Pricing $0.02 0.003 lb V PEB Lower Base Module 3 Commodity Pricing $0.04 0.01 lb V PEB Lower Base Module 4 Assembly $0.03 0.0600 lb V PEB Lower Base Module 4 Washed $0.03 0.0600 lb V PEB Lower Base Module 4 Plated $0.03 0.0600 lb V PEB Lower Base Module 4 Steel - 1008 $0.03 0.0600 lb V PEB Lower Base Module 1 Assembly $0.17 0.2930 lb V PEB Lower Base Module 1 Weldment $0.15 0.2900 lb V PEB Lower Base Module 1 Washed $0.15 0.2900 lb V PEB Lower Base Module V PEB Lower Base Module 1 Plated $0.15 0.2900 lb V PEB Lower Base Module 1 Steel - 1008 $0.15 0.2900 lb V PEB Lower Base Module 1 Commodity Pricing $0.02 0.003 lb V PEB Lower Base Module 1 Assembly $0.20 0.3230 lb V PEB Lower Base Module 1 Weldment $0.18 0.3200 lb V PEB Lower Base Module 1 Washed $0.18 0.3200 lb V PEB Lower Base Module 1 Plated $0.18 0.3200 lb V PEB Lower Base Module 1 Steel - 1008 $0.18 0.3200 lb V PEB Lower Base Module 1 Commodity Pricing $0.02 0.003 lb V PEB Lower Base Module 6 Commodity Pricing $0.02 0 lb V PEB Lower Base Module 9 Commodity Pricing $0.03 0 lb V PEB Lower Base Module 5 Commodity Pricing $0.01 0 lb V PEB Lower Base Module 6 Commodity Pricing $0.02 0 lb V PEB Lower Base Module 1 Commodity Pricing $0.16 0.0072 lb V PEB Lower Base Module 1 Commodity Pricing $0.09 0.0034 lb V PEB Lower Base Module 2 Commodity Pricing $0.02 0.0033 lb V PEB Lower Base Module

10 Commodity Pricing $0.01 0.0036 lb V PEB Lower Base Module 1 Assembly $0.42 0.0781 lb 1 Washed $0.40 0.0765 lb 1 Plated $0.40 0.0765 lb 1 Stamped $0.40 0.0765 lb
1 Copper $0.40 0.0765 lb

1 Commodity Pricing $0.02 0.0016 lb

2 Commodity Pricing $0.02 0.0033 lb

1 Commodity Pricing $0.01 0.0036 lb

1 Assembly $2.06 0.1345 lb

1 Washed $2.04 0.1329 lb

1 Stamped $2.04 0.1329 lb

1 Copper $2.04 0.1329 lb

1 Commodity Pricing $0.02 0.0016 lb

3 Commodity Pricing $0.02 0.0033 lb

1 Assembly $0.47 0.0466 lb

1 Washed $0.45 0.0450 lb

1 Stamped $0.45 0.0450 lb

1 Copper $0.45 0.0450 lb

1 Commodity Pricing $0.02 0.0016 lb

2 Commodity Pricing $0.02 0.0033 lb

1 Assembly $1.79 0.0942 lb

1 Washed $1.77 0.0926 lb

1 Stamped $1.77 0.0926 lb

1 Copper $1.77 0.0926 lb

1 Commodity Pricing $0.02 0.0016 lb

2 Commodity Pricing $0.02 0.0033 lb

1 Copper $1.31 0.0896 lb

1 Copper $1.31 0.0896 lb

1 Copper $1.31 0.0896 lb

1 Commodity Commodity Pricing Pricing $0.00 0.0289 lb

1 Commodity Pricing $0.02 0.0033 lb

2 Commodity Pricing $0.01 0.0036 lb

1 Commodity Pricing $0.00 0.0244 lb

1 Commodity Pricing $0.03 0.0073 lb

1 Assembly $106.03 0.8090 lb V Main Circuit Board GD114438-2-3

1 Testing $106.03 0.8090 lb V Main Circuit Board GD114438-2-3

1 Conformal Coat $106.03 0.8090 lb V Main Circuit Board GD114438-2-3

1 Thru-hole $106.03 0.8090 lb V Main Circuit Board GD114438-2-3

1 Thru-hole $91.95 0.8090 lb V Main Circuit Board GD114438-2-3

1 SMT $83.65 0.8090 lb V Main Circuit Board GD114438-2-3

1 Commodity Pricing $8.75 0.809 lb V Main Circuit Board GD114438-2-3

1 Assembly $6.08 - lb V Main Circuit Board GD114438-2-3

93C66B-I/ST-ND 1 Commodity Pricing $0.28 0 lb V Main Circuit Board GD114438-2-3

LT1461DHS8-3#PBF-ND 1 Commodity Pricing $1.15 0 lb V Main Circuit Board GD114438-2-3

IR2101STR-ND 1 Commodity Pricing $1.03 0 lb V Main Circuit Board GD114438-2-3

641-1099-6-ND 1 Commodity Pricing $0.28 0 lb V Main Circuit Board GD114438-2-3

V Resistors 220 Commodity Pricing $0.01 0 lb V Main Circuit Board GD114438-2-3

V Capacitors 114 Commodity Pricing $0.01 V Main Circuit Board GD114438-2-3

1 Assembly $56.75 - lb V Main Circuit Board GD114438-2-3

HC6F800-S 4 Commodity Pricing $0.00 0 lb V Main Circuit Board GD114438-2-3

NTD20P06LT4GOSCT-ND 2 Commodity Pricing $0.49 0 lb V Main Circuit Board GD114438-2-3
R5F61668RN50FPV-ND 1 Commodity Pricing $15.74 0 lb V Main Circuit Board GD114438-2-3

AD2S1200WSTZ-ND 1 Commodity Pricing $3.50 0 lb V Main Circuit Board GD114438-2-3

445-2221-2-ND 2 Commodity Pricing $0.30 0 lb V Main Circuit Board GD114438-2-3

APIC-S03 1 Commodity Pricing $24.09 0 lb V Main Circuit Board GD114438-2-3

24LC16BH-I/SN-ND 1 Commodity Pricing $0.28 0 lb V Main Circuit Board GD114438-2-3

IR21094SPBF-ND 1 Commodity Pricing $1.03 0 lb V Main Circuit Board GD114438-2-3

296-11431-5-ND 1 Commodity Pricing $0.71 0 lb V Main Circuit Board GD114438-2-3

296-7354-2-ND 3 Commodity Pricing $0.24 0 lb V Main Circuit Board GD114438-2-3

DSS6-0025BS-ND 2 Commodity Pricing $0.54 0 lb V Main Circuit Board GD114438-2-3

NTD70N03RT4GOSCT-ND 1 Commodity Pricing $0.36 0 lb V Main Circuit Board GD114438-2-3

CMS04QMTR-ND 4 Commodity Pricing $0.29 0 lb V Main Circuit Board GD114438-2-3

FFD06UP20SCT-ND 3 Commodity Pricing $0.19 0 lb V Main Circuit Board GD114438-2-3

296-14516-6-ND 1 Commodity Pricing $0.33 0 lb V Main Circuit Board GD114438-2-3

BAT 63-02V E6327-ND 4 Commodity Pricing $0.11 0 lb V Main Circuit Board GD114438-2-3

PC844 1 Commodity Pricing $0.60 0 lb V Main Circuit Board GD114438-2-3

641-1099-6-ND-1 3 Commodity Pricing $0.28 0 lb V Main Circuit Board GD114438-2-3

497-2529-2-ND 22 Commodity Pricing $0.08 0 lb V Main Circuit Board GD114438-2-3

88 Commodity Pricing $0.01 0 lb V Main Circuit Board GD114438-2-3

106 Commodity Pricing $0.01 V Main Circuit Board GD114438-2-3

1 Assembly $12.07 - lb V Main Circuit Board GD114438-2-3

2 Commodity Pricing $0.66 0 lb V Main Circuit Board GD114438-2-3

2 Commodity Pricing $0.36 0 lb V Main Circuit Board GD114438-2-3

4 Commodity Pricing $0.38 0 lb V Main Circuit Board GD114438-2-3

4 Commodity Pricing $1.02 0 lb V Main Circuit Board GD114438-2-3

2 Commodity Pricing $0.97 0 lb V Main Circuit Board GD114438-2-3

1 Commodity Pricing Commodity Pricing $0.22 0 lb V Main Circuit Board GD114438-2-3 V Main Circuit Board GD114438-2-3

1 Commodity Pricing $0.22 0 lb V Main Circuit Board GD114438-2-3

1 Commodity Pricing $0.53 0 lb V Main Circuit Board GD114438-2-3

1 Commodity Pricing $1.20 0 lb V Main Circuit Board GD114438-2-3

1 Commodity Pricing $0.31 0 lb V Main Circuit Board GD114438-2-3

1 Commodity Pricing $0.01 V Main Circuit Board GD114438-2-3

1 Commodity Pricing $3.75 0 lb V Main Circuit Board GD114438-2-3

1 Commodity Pricing $1.75 0 lb V Main Circuit Board GD114438-2-3

8 Commodity Pricing $0.35 0 lb V Main Circuit Board GD114438-2-3

2 Commodity Pricing $7.04 0 lb V Main Circuit Board GD114438-2-3

13 Commodity Pricing $0.10 0.003 lb

1 Assembly $0.63 0.0223 lb

1 Depanel $0.63 0.0223 lb

1 Commodity Pricing $0.57 0.0223 lb

2 Commodity Pricing $0.03 0 lb

3 Commodity Pricing $0.10 0.003 lb

1 Commodity Pricing $0.02 0.0033 lb

4 Assembly $0.18 0.0016 lb

4 Washed $0.16 - lb

4 Stamped $0.16 - lb

4 Copper $0.16 - lb

4 Commodity Pricing $0.02 0.0016 lb
8 Commodity Pricing $0.01 0.0036 lb 1 Commodity Pricing $0.15 0.0072 lb 1 Assembly $1.57 1.2300 lb 1 Washed $1.37 1.2300 lb 1 Machined $1.37 1.2300 lb 1 Trimmed $1.37 1.2300 lb 1 Casting $1.37 1.2300 lb 1 A380 $1.37 1.2300 lb 1 Commodity Pricing $0.20 0 lb 1 Commodity Pricing $0.02 0.0093 lb 6 Commodity Pricing $0.02 0.0085 lb 6 Commodity Pricing $0.02 0.008 lb



Indented Bill of Materials

V PEB Connector Module 8 Pin

.

Level Symbol Name Number Qty Material Piece Cost Weight

. 0 V PEB Connector Module 8 Pin w-stitching 1 $7.05 3.9689 lb

. 1 V PEB Conn Mod 8 Pin w-PCB mnted 1 $7.05 3.9689 lb

. 2 V PEB Conn Mod 8 Pin, Housing Assy 1 $1.88 0.7235 lb

. 3 V PEB Conn Mod 8 Pin, Housing Assy 1 $0.66 0.5871 lb

. 4 V PEB Con Mod 8 Pin, Hsg Machined 1 $0.66 0.5871 lb

. 5 V PEB Con Mod 8 Pin, Hsg Trim 1 $0.66 0.5871 lb

. 6 V PEB Con Mod 8 Pin, Hsg Cast 1 $0.66

. 7 V PEB Connector Module 8 Pin, Housing Cast-Materia 1 A380 $0.66

. 3 V Seal PEB Connector 1 Commodity Pricing $0.07 0.0016 lb

. 3 V PEB 8 pin Connector Header 1 Commodity Pricing $0.91 0.1178 lb

. 3 V Bolt 8 Pin Connector Housing 2 Commodity Pricing $0.02 0.0085 lb

. 3 V Vent Cap PEB 8 pin Module 1 Commodity Pricing $0.20 0.0000 lb

. 2 V PEB Connector Module 8 Pin, PCB Assy 1 $5.06 2.7179 lb

. 3 V PEB Con Mod 8 Pin, PCB Depaneled 1 $5.06 2.7179 lb

. 4 V PEB Con Mod 8 Pin, PCB Conformal Coated 1 $5.06 2.7179 lb

. 5 V PEB Con Mod 8 Pin, PCB w thru hole parts 1 $5.06 2.7179 lb

. 6 V PEB Con Mod 8 Pin, PCB w SMT parts 1 $3.56

. 7 V PEB Con Mod 8 Pin, PCB bare board 1 Commodity Pricing $1.78

. 7 V PEB Con Mod 8 Pin, PCB Top side components 1 $1.34

. 8 V Resistors - Caps V Resistors - Caps 87 Commodity Pricing Commodity Pricing $0.01

. 8 V Transistors 3 Commodity Pricing $0.03

. 8 V Capacitor - odd form 1 Commodity Pricing $0.03

. 8 V Capacitor 5PW 33 50V 1 Commodity Pricing $0.35

. 6 V Inductor Asm, Coil, Large 1 Commodity Pricing $1.50

. 2 V Bolt 8 pin PEB PCB to housing 7 Commodity Pricing $0.02 0.0030 lb

. 0 V Seal PEB Cover 1 Commodity Pricing $0.11 0.0055 lb

. 0 V Cover, PEB 8 pin Module 1 $0.21 0.3164 lb

. 1 V Cover, PEB 8 pin Module-Stamping 1 $0.21 0.3164 lb

. 2 V Cover, PEB 8 pin Module-Blank 1 Galvinized Steel - G60 $0.21 0.3164 lb

. 0 V Bolt PEB Module Cover 6 Commodity Pricing $0.02 0.0065 lb
Weight (Total)

$7.05 3.9689 lb

# 3.9689 lb

$1.88 0.7235 lb

0.5871 lb $0.66 0.5871 lb

0.5871 lb $0.66 0.5871 lb

0.5871 lb $0.66 0.5871 lb

0.5871 lb $0.66 0.5871 lb

0.5871 lb $0.66 0.5871 lb

0.0016 lb $0.07 0.0016 lb

0.1178 lb $0.91 0.1178 lb

0.0085 lb $0.04 0.0170 lb

0.0000 lb $0.20 0.0000 lb

$5.06 2.7179 lb

2.7179 lb $5.06 2.7179 lb

2.7179 lb $5.06 2.7179 lb

2.7179 lb $5.06 2.7179 lb

2.4600 lb $3.56 2.4600 lb

1.2300 lb $1.78 1.2300 lb

1.2300 lb $1.34 1.2300 lb

0.0000 lb $0.87 0.0000 lb

Piece Cost 

(Total)

0.0000 lb $0.09 0.0000 lb

0.0000 lb $0.03 0.0000 lb

0.0000 lb $0.35 0.0000 lb

0.2579 lb $1.50 0.2579 lb

$0.11 0.0210 lb

$0.11 0.0055 lb

$0.21 0.3164 lb

# 0.3164 lb

$0.21 0.3164 lb

$0.12 0.0390 lb
Page: 1 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Assembly of Body Structure Subsystem Components Part Number: 030100-N0402-01 Weekly Component Volume: Packaging Specification:

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

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 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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)

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

B Purchase Part - High Impact Item (Full Cost Mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Assembly of Body Structure Subsystem Components Part Number: 030100-N0402-01 Weekly Component Volume: Packaging Specification:

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

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

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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)

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

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

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 3 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Assembly of Body Structure Subsystem Components Part Number: 030100-N0402-01 Weekly Component Volume: Packaging Specification:

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

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

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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

2 0 $0.00 $0.00 $0.00 $0.00 $0.00

3 0 $0.00 $0.00 $0.00 $0.00 $0.00

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

5 0 $0.00 $0.00 $0.00 $0.00 $0.00

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

7 0 $0.00 $0.00 $0.00 $0.00 $0.00

8 0 $0.00 $0.00 $0.00 $0.00 $0.00

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly. 9 0 $0.00 $0.00 $0.00 $0.00 $0.00

10 0 $0.00 $0.00 $0.00 $0.00 $0.00

11 0 $0.00 $0.00 $0.00 $0.00 $0.00

12 0 $0.00 $0.00 $0.00 $0.00 $0.00

13 0 $0.00 $0.00 $0.00 $0.00 $0.00

14 0 $0.00 $0.00 $0.00 $0.00 $0.00

15 0 $0.00 $0.00 $0.00 $0.00 $0.00

16 0 $0.00 $0.00 $0.00 $0.00 $0.00

17 0 $0.00 $0.00 $0.00 $0.00 $0.00

18 0 $0.00 $0.00 $0.00 $0.00 $0.00

19 0 $0.00 $0.00 $0.00 $0.00 $0.00

20 0 $0.00 $0.00 $0.00 $0.00 $0.00

21 0 $0.00 $0.00 $0.00 $0.00 $0.00

22 0 $0.00 $0.00 $0.00 $0.00 $0.00

23 0 $0.00 $0.00 $0.00 $0.00 $0.00

24 0 $0.00 $0.00 $0.00 $0.00 $0.00

25 0 $0.00 $0.00 $0.00 $0.00 $0.00

26 0 $0.00 $0.00 $0.00 $0.00 $0.00

27 0 $0.00 $0.00 $0.00 $0.00 $0.00

28 0 $0.00 $0.00 $0.00 $0.00 $0.00

29 0 $0.00 $0.00 $0.00 $0.00 $0.00

30 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.00

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $0.00

T1 or OEM Total Manufacturing Cost: $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- #N/A #N/A #N/A #N/A #N/A

Supplier for Subassembly.

3

1

Notes: 

T1 or OEM Mark-Up Rates: a) Items 1,2, & 3 must a----- ----- ----- ----- #N/A #N/A #N/A #N/A #N/A

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- #N/A #N/A #N/A #N/A #N/A

Base Cost Impact to Vehicle: $0.00 $0.00 $0.00 $0.00 #N/A #N/A #N/A #N/A #N/A #N/A $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: #N/A

a) Items 1,2, & 3 must a

Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 4 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class ) Components per Engine: OEM/T1 Classification:

System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah) Annual Component Volume: Shipping Method:

Component Description: Assembly of Body Structure Subsystem Components Part Number: 030100-N0402-01 Weekly Component Volume: Packaging Specification:

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

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

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Mild Hybrid - Start-Stop Technology

MARK-UP COSTS Manufacturing Costs 

Costs Broken Out In

TOTAL COSTS TOOLING & INVESTMENT

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)

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 58 1000 6 57447

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike 

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote Expendable Packaging in Piece Cost: $0.00 $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0

Packaging Cost Total: $0.000

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet - 8 Cells (2x4)xHeight of Pallet, =$20.00

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

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 $0.00 $0.00 $0.00 $0.00 $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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

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

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

Purchase Part - High Impact Item (Full Cost Mapping)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

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

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

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00

$0.00

2

Notes: 

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

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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

Projected Operating Pattern Minimum Calculated Cycles Time 

MANUFACTURING ASSUMPTIONS

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

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

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

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! -

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! -

#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! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 10 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

#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! -

#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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 11 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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)

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/21/2012

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:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411