### 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 Pow **er Electric Center (PEC) Subsy stem** 

1 **00 Assembly of Power Electric Center (PEC) Subsystem**  **0.91 $**  **5.36**

**$ 0.83** 

**$ 7.10** 

**$**

**-**

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### 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** 

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### 3 **75 Bracket**  **2.47 $**  **0.67**

**$ 1.05** 

**$ 4.20** 

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**$ 0.55** 

**$ 0.57** 

**$ 0.21** 

**$ 1.39** 

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**- $** 

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**- $** 

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# BASE TECHNOLOGY GENERAL PART INFORMATION:

**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)**ItemSubsystem 

### 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** 

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### 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 TECHNOLOGY GENERAL PART INFORMATION:

**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)**ItemSubsystem 

### 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)

**245.20 $**  **39.18**

**$ 83.29** 

**$ 367.68** 

**$ 2.54** 

**$ 25.50** 

**$ 29.08** 

**$ 14.47** 

**$ 71.60** 

**$ 0.12** 

**$ 439.40** 

**$**

**-**

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**-**

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### -

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**$ SUBSYSTEM ROLL-UP** 

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 Pow **er Electric Center (PEC) Subsy stem** 

1 **00**

2 **01**

3 **75**

4 **80**

5 **85**ItemSubsystem 

# 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

**- $** 

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**$ 241.82** 

**$ 33.15** 

**$ 81.42** 

**$ 356.39** 

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**$ 24.95** 

**$ 28.51** 

**$ 14.26** 

**$ 70.21** 

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**$**

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# 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**

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**Assembly) Total** 

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**Cost**

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**/ Assembly) Net** 

**Component/**

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**Cost Impact to**

**OEM System** 

**ED&T/R&D**

**(x1000) Tooling** 

**(x1000) System** 

**ED&T/R&D**

**(x1000) Tooling** 

**(x1000) Investment** 

**(X1000)**



### 6 **99**

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### 0 **0**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

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### 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

DRAFTItemSubsystem 

# 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 Pow **er Electric Center (PEC) Subsy stem** 

1 **00**

2 **01**

3 **75**

4 **80**

5 **85**ItemSubsystem 

# 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

DRAFTItemSubsystem 

# 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 Pow **er Electric Center (PEC) Subsy stem** 

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 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)**ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**

MarkupAssembly



### Name/Description 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)**SubassemblyComponentSub-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)**ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**

MarkupAssembly



### Name/Description 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)**SubassemblyComponentSub-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 Pow **er Electric Center (PEC) Subsy stem** 

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)**ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



### Name/DescriptionQTY/Subsystem 

### NotesSubassemblyComponentSub-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)**ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



### Name/DescriptionQTY/Subsystem 

### NotesSubassemblyComponentSub-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 Pow **er Electric Center (PEC) Subsy stem** 

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 1 **00 Assembly of Power Electric Center (PEC) Subsystem** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 2 **01 Power Electronics Control Center** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 3 **75 Bracket** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$** 

# BASE TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)**SubassemblyComponentSub-Subsystem 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

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

# 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 Pow **er Electric Center (PEC) Subsy stem** 

1 **00 Assembly of Power Electric Center (PEC) Subsystem** 

2 **01 Power Electronics Control Center** 

3 **75 Bracket** QTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

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

# 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 (W eeks/Year): OEM Plant Location:

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

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: 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** 

## We ekly Component Volume: Packaging Specification: **Not Applicable**



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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

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

1 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 Into Categories with Quantity per Assembly Taken into Account

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Hybrid - Start-Stop Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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 (W eeks/Year): OEM Plant Location:

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

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: 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** 

## We ekly Component Volume: Packaging Specification: **Not Applicable**



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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

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

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Hybrid - Start-Stop Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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 (W eeks/Year): OEM Plant Location:

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

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: 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** 

## We ekly Component Volume: Packaging Specification: **Not Applicable**



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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

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

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Hybrid - Start-Stop Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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 Sub

Assembly.

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 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: 4 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

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

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: 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** 

## We ekly Component Volume: Packaging Specification: **Not Applicable**



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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

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

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Hybrid - Start-Stop Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Net Cost Impact to Vehicle: $7.10** 

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment**

**(%) Total # of** 

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: 

### 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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

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

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.87 $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**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

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: R** **e f** **e r** **e n** **c e** **#** 

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



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

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

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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: R** **e f** **e r** **e n** **c e** **#** 

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



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

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** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

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

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.10**

**$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: R** **e f** **e r** **e n** **c e** **#** 

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



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

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

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

File: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: R** **e f** **e r** **e n** **c e** **#** 

### 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.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**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: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **#DIV/0! #DIV/0!** 

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

**#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: R** **e f** **e r** **e n** **c e** **#** 

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



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

V Nut, PEB to BIW 180780-N0402-01



### V Bolt, PEB to BIW 180780-N0402-02



### V Bolt 12-V Cable PEB ( Same**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

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

-

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

-

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

-

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

-

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

-



### 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: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File: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**ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**

MarkupAssembly



### Name/Description Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)**SubassemblyComponentSub-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**ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-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 (W eeks/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**  We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year:

**Item R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y Primary Process Description**  **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  **Material**

**Cost $/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n End Item** 

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark-up**

**Rate Total** 

**Mark-up**

**Cost**



### .

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 COSTS MANUFACTURING RATES**  **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 Q **uote**

**Modification Quote** 

### Di **fferential Q uote (Q**  **uote S um**  **mary in cludes costing for both T**  **echnology 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 180703-N0402-14 **1** Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech. Assembly, LC **240 1**  **1 1**  0.094 **$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** 

V Copper Relay 2 Assembly 180703-N0402-14 Assembly T1 Assembly, Mark-up Applied @ Bottom. Not Applicable General Assembly Mech. Assembly, LC **$100.00 $100.00** 

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 (W eeks/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**  We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year:

**Item R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y Primary Process Description**  **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  **Material**

**Cost $/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n End Item** 

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark-up**

**Rate Total** 

**Mark-up**

**Cost GENERAL COMPONENT INFORMATION**  **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES 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 Q **uote**

**Modification Quote** 

### Di **fferential Q uote (Q**  **uote S um**  **mary in cludes costing for both T**  **echnology 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 180706-N0402-11 **1** Cold Chamber Die Casting Machine (1000-1800 Ton) T1 Assembly, Mark-up Applied @ Bottom. Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, MS **172 1**  **1 1**  1.242 **$1.10 $41.48**  **$197.05 $197.05**  **$1.37 $0.24**  **$1.14 $2.75**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00** 

V Cover PEB Unit-Cast-Material 180706-N0402-11 Cold Chamber Die Casting Machine (1000-1800 Ton) T1 Assembly, Mark-up Applied @ Bottom. Aluminum-A380, Cast Mold/Cast/Sinter Operator Diecast, MS **$197.05 $197.05** 



### . .

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 (W eeks/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**  We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year:

**Item R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y Primary Process Description**  **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  **Material**

**Cost $/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n End Item** 

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark-up**

**Rate Total** 

**Mark-up**

**Cost GENERAL COMPONENT INFORMATION**  **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES 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 Q **uote**

**Modification Quote** 

### Di **fferential Q uote (Q**  **uote S um**  **mary in cludes costing for both T**  **echnology 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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** **- t** **r a** **n s** **i t** **I n** **v e** **n t** **o r** **y R** **e q** **u i** **r e** **m e** **n t** **s (** **W e** **e k** **s )** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** **- t** **r a** **n s** **i t** **I n** **v e** **n t** **o r** **y R** **e q** **u i** **r e** **m e** **n t** **s (** **P a** **r t** **s )** 



### Rack/Pallet Investment Amortization: **$0.123 $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: R** **e f** **e r** **e n** **c e** **# 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) T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  **Material Labor**  **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) End Item** 

**Scrap SG&A**  **Profit ED&T-R&D** **T o** **t a** **l M** **a r** **k u** **p C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) Process & Equipment Assumptions**  **Tool, Fixture and Gauge Assumptions Days/We** 

**ek Shifts./** 

**Day Hrs./** 

**Shift Hrs./ Wk**  **Wks./ Yr. Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** 

**$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 Process Information**  **Gross Mark-up Costs x Quantity 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** 

**$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 Assembly 180703-N0402-14



### . 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: R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number**



### . **GENERAL COMPONENT INFORMATION** 

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



### . 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) T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  **Material Labor**  **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) End Item** 

**Scrap SG&A**  **Profit ED&T-R&D** **T o** **t a** **l M** **a r** **k u** **p C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) Process & Equipment Assumptions**  **Tool, Fixture and Gauge Assumptions Days/We** 

**ek Shifts./** 

**Day Hrs./** 

**Shift Hrs./ Wk**  **Wks./ Yr. Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y**  **Process Information Gross Mark-up Costs x Quantity**  **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** 

**$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** 



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



### .



## 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: R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number**



### . **GENERAL COMPONENT INFORMATION** 

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

**T1 High Assembly Complexity**

**Stackable Totes (Flexcon) T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  **Material Labor**  **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) End Item** 

**Scrap SG&A**  **Profit ED&T-R&D** **T o** **t a** **l M** **a r** **k u** **p C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) Process & Equipment Assumptions**  **Tool, Fixture and Gauge Assumptions Days/We** 

**ek Shifts./** 

**Day Hrs./** 

**Shift Hrs./ Wk**  **Wks./ Yr. Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y**  **Process Information Gross Mark-up Costs x Quantity**  **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: R** **e f** **e r** **e n** **c e** **# 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.**C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**

**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 **Project Process Requirement Minimum Calculated Cycles Time** 



### . 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

**31.96** 15 1 1 15 **1.0 1.0**  **240 15.00**  1.00



### . V Copper Relay 2 Assembly 180703-N0402-14



### . 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: R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number**



### . **GENERAL COMPONENT INFORMATION** 

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



### . 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**C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s Project Process Requirement**  **Minimum Calculated Cycles Time**

**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

**31.96** 38 1 2 42 **1.0 1.0**  **172 20.90**  1.00



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



### .



## 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: R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number**



### . **GENERAL COMPONENT INFORMATION** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s Project Process Requirement**  **Minimum Calculated Cycles Time**



### 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 (W eeks/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**  We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year:

**Item R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y Primary Process Description**  **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  **Material**

**Cost $/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n End Item** 

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark-up**

**Rate Total** 

**Mark-up**

**Cost**



### .

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 COSTS MANUFACTURING RATES**  **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 Q uote** 

**Modification Quote** 

### Di **ffer ential Quote (Q**  **uote Sum ma**  **ry includes costing for both T echnology 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 180703-N0402-47 **1** Vertical Stamping Press, Tonnage 0-60 T1 Assembly, Mark-up Applied @ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator 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** 

V Terminal Plate Capcitor Anode-Stamp 180703-N0402-47 Vertical Stamping Press, Tonnage 0-60 T1 Assembly, Mark-up Applied @ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals

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 **$0.00** $0.11 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

- Assembly.



### 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 (W eeks/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**  We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year:

**Item R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y Primary Process Description**  **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  **Material**

**Cost $/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n End Item** 

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark-up**

**Rate Total** 

**Mark-up**

**Cost 9,574** 

**10 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **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 Q uote** 

**Modification Quote** 

### Di **ffer ential Quote (Q**  **uote Sum ma**  **ry includes costing for both T echnology 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 (W eeks/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**  We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year:

**Item R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y Primary Process Description**  **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  **Material**

**Cost $/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n End Item** 

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark-up**

**Rate Total** 

**Mark-up**

**Cost 9,574** 

**10 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **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 Q uote** 

**Modification Quote** 

### Di **ffer ential Quote (Q**  **uote Sum ma**  **ry includes costing for both T echnology Packages)** 

**Packaging Cost:**

**Net Cost Impact to Vehicle:**

**Packaging Lump Sum** **C o** **s t** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **T o** **t a** **l N** **u m** **b e** **r o** **f P** **a l** **l e** **t s** **/ R** **a c** **k s** **R e** **q u** **i r** **e d** **N u** **m b** **e r** **o f** **P a** **r t** **s p** **e r** **P a** **l l** **e t** **/ R** **a c** **k S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n -** **t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n -** **t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)** 

### 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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** **- t** **r a** **n s** **i t** **I n** **v e** **n t** **o r** **y R** **e q** **u i** **r e** **m e** **n t** **s (** **W e** **e k** **s )** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** **- t** **r a** **n s** **i t** **I n** **v e** **n t** **o r** **y R** **e q** **u i** **r e** **m e** **n t** **s (** **P a** **r t** **s )** 



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **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: R** **e f** **e r** **e n** **c e** **# 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 T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  **Material Labor**  **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) End Item** 

**Scrap SG&A**  **Profit ED&T-R&D** **T o** **t a** **l M** **a r** **k u** **p C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) Process & Equipment Assumptions**  **Tool, Fixture and Gauge Assumptions Days/We** 

**ek Shifts./** 

**Day Hrs./** 

**Shift Hrs./ Wk**  **Wks./ Yr. Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** 

**$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 Process Information**  **Gross Mark-up Costs x Quantity 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**

**$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 Anode-Stamp 180703-N0402-47

. 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: R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number**



### . **GENERAL COMPONENT INFORMATION** 

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

. 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 T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  **Material Labor**  **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) End Item** 

**Scrap SG&A**  **Profit ED&T-R&D** **T o** **t a** **l M** **a r** **k u** **p C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) Process & Equipment Assumptions**  **Tool, Fixture and Gauge Assumptions Days/We** 

**ek Shifts./** 

**Day Hrs./** 

**Shift Hrs./ Wk**  **Wks./ Yr. Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "**  **North America**

**North America**

**FOB Ship Point**

**Projected Operating Pattern Minimum Calculated Cycles Time**  **MANUFACTURING ASSUMPTIONS**

**Manufacturing Costs x Quantity Process Information**  **Gross Mark-up Costs x Quantity 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** 

**$0.00 $0.12**  **$0.12 $0.12** 

. 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 **$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: R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number**



### . **GENERAL COMPONENT INFORMATION** 

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

**T1 High Assembly Complexity T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  **Material Labor**  **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) End Item** 

**Scrap SG&A**  **Profit ED&T-R&D** **T o** **t a** **l M** **a r** **k u** **p C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) Process & Equipment Assumptions**  **Tool, Fixture and Gauge Assumptions Days/We** 

**ek Shifts./** 

**Day Hrs./** 

**Shift Hrs./ Wk**  **Wks./ Yr. Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "**  **North America**

**North America**

**FOB Ship Point**

**Projected Operating Pattern Minimum Calculated Cycles Time**  **MANUFACTURING ASSUMPTIONS**

**Manufacturing Costs x Quantity Process Information**  **Gross Mark-up Costs x Quantity 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: R** **e f** **e r** **e n** **c e** **# 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.**L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**

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

2 1 1 2 **1.0 1.0**  **2118 1.70**  0.50

. V Terminal Plate Capcitor Anode-Stamp 180703-N0402-47

. 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: R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number**



### . **GENERAL COMPONENT INFORMATION** 

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

. 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**L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s 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: R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number**



### . **GENERAL COMPONENT INFORMATION** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s 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 (W eeks/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**  We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year:

**Item R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y Primary Process Description**  **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  **Material**

**Cost $/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n End Item** 

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark-up**

**Rate Total** 

**Mark-up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y**



### .

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 COSTS MANUFACTURING RATES**  **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 Q uote** 

**Modification Quote** 

### Di **ffer ential Quote (Q**  **uote Sum ma**  **ry includes costing for both T echnology 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 (W eeks/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**  We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year:

**Item R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y Primary Process Description**  **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  **Material**

**Cost $/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n End Item** 

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark-up**

**Rate Total** 

**Mark-up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y 9,574** 

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **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 Q uote** 

**Modification Quote** 

### Di **ffer ential Quote (Q**  **uote Sum ma**  **ry includes costing for both T echnology 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 180703-N0402-108 **8** Commodity Pricing S **$0.00** $0.35 **$0.00 $2.80** 

V Flexible Connector 180703-N0402-108 Commodity Pricing

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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** **- t** **r a** **n s** **i t** **I n** **v e** **n t** **o r** **y R** **e q** **u i** **r e** **m e** **n t** **s (** **W e** **e k** **s )** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** **- t** **r a** **n s** **i t** **I n** **v e** **n t** **o r** **y R** **e q** **u i** **r e** **m e** **n t** **s (** **P a** **r t** **s )** 



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **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 (W eeks/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**  We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year:

**Item R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y Primary Process Description**  **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  **Material**

**Cost $/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n End Item** 

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark-up**

**Rate Total** 

**Mark-up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y 9,574** 

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **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 Q uote** 

**Modification Quote** 

### Di **ffer ential Quote (Q**  **uote Sum ma**  **ry includes costing for both T echnology 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: R** **e f** **e r** **e n** **c e** **# 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 T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  **Material Labor**  **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) End Item** 

**Scrap SG&A**  **Profit ED&T-R&D** **T o** **t a** **l M** **a r** **k u** **p C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) Process & Equipment Assumptions**  **Tool, Fixture and Gauge Assumptions Days/We** 

**ek Shifts./** 

**Day Hrs./** 

**Shift Hrs./ Wk**  **Wks./ Yr. Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** 

**$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 Process Information**  **Gross Mark-up Costs x Quantity 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: R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number**



### . **GENERAL COMPONENT INFORMATION** 

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

. 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 T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  **Material Labor**  **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) End Item** 

**Scrap SG&A**  **Profit ED&T-R&D** **T o** **t a** **l M** **a r** **k u** **p C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) Process & Equipment Assumptions**  **Tool, Fixture and Gauge Assumptions Days/We** 

**ek Shifts./** 

**Day Hrs./** 

**Shift Hrs./ Wk**  **Wks./ Yr. Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "**  **Projected Operating Pattern Minimum Calculated Cycles Time**  **MANUFACTURING ASSUMPTIONS**

**Manufacturing Costs x Quantity Process Information**  **Gross Mark-up Costs x Quantity 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** 

**$2.80 $2.80** 

. V Flexible Connector 180703-N0402-108

. 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: R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number**



### . **GENERAL COMPONENT INFORMATION** 

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

**T1 High Assembly Complexity T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  **Material Labor**  **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) End Item** 

**Scrap SG&A**  **Profit ED&T-R&D** **T o** **t a** **l M** **a r** **k u** **p C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) Process & Equipment Assumptions**  **Tool, Fixture and Gauge Assumptions Days/We** 

**ek Shifts./** 

**Day Hrs./** 

**Shift Hrs./ Wk**  **Wks./ Yr. Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "**  **Projected Operating Pattern Minimum Calculated Cycles Time**  **MANUFACTURING ASSUMPTIONS**

**Manufacturing Costs x Quantity Process Information**  **Gross Mark-up Costs x Quantity 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: R** **e f** **e r** **e n** **c e** **# 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.**L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**

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: R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number**



### . **GENERAL COMPONENT INFORMATION** 

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

. 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**L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s 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: R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number**



### . **GENERAL COMPONENT INFORMATION** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** **P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s 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 (W eeks/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**  We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year:

**Item R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y Primary Process Description**  **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  **Material**

**Cost $/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n End Item** 

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark-up**

**Rate Total** 

**Mark-up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y**



### 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 COSTS**  **MANUFACTURING RATES 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 Q uote** 

**Modification Quote** 

### Di **ffe ren**  **tial Quote (Quote S um**  **mary in clu**  **des costing for both T echnology 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 (W eeks/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**  We ekly Component Volume: Packaging Specification:

**Component Quote Level:** Estimated Product Life: Production Year:

**Item R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y Primary Process Description**  **OEM/Supplier Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  **Material**

**Cost $/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n End Item** 

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark-up**

**Rate Total** 

**Mark-up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y 9,574** 

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**



### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES 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 Q uote** 

**Modification Quote** 

### Di **ffe ren**  **tial Quote (Quote S um**  **mary in clu**  **des costing for both T echnology 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 C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **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: R** **e f** **e r** **e n** **c e** **# 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 T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  **Material Labor**  **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) End Item** 

**Scrap SG&A**  **Profit ED&T-R&D** **T o** **t a** **l M** **a r** **k u** **p C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) Process & Equipment Assumptions**  **Tool, Fixture and Gauge Assumptions Days/We** 

**ek Shifts./** 

**Day Hrs./** 

**Shift Hrs./ Wk**  **Wks./ Yr. Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e** 

**$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 **Process Information Gross Mark-up Costs x Quantity**  **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** 

**$0.09 $0.09** 

. 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 **$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: R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number** 

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

. 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 T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  **Material Labor**  **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) End Item** 

**Scrap SG&A**  **Profit ED&T-R&D** **T o** **t a** **l M** **a r** **k u** **p C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **) Process & Equipment Assumptions**  **Tool, Fixture and Gauge Assumptions Days/We** 

**ek Shifts./** 

**Day Hrs./** 

**Shift Hrs./ Wk**  **Wks./ Yr. Hrs./ Yr.** **P c** **s .** **. /** **H r** **. (** **1 0** **0 %** **E f** **f .** **. )** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n "** **S e** **c .** **" E** **f f** **i c** **i e** **n c** **y %** **P c** **s .** **. /** **H r** **. @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **C y** **c l** **e T** **i m** **e /** **O p** **e r** **a t** **i o** **n @** **S t** **a t** **e d** **E f** **f i** **c i** **e n** **c y** **" S** **e c** **. "** **L e** **a n** **D e** **s i** **g n** **C a** **l c** **u l** **a t** **i o** **n f** **o r** **C o** **m p** **l e** **t e** **P r** **o c** **e s** **s T** **i m** **e "** **S e** **c .** **" P** **a r** **a l** **l e** **l O** **p e** **r a** **t i** **o n** **s /** **M a** **c h** **i n** **e o** **r S** **t a** **t i** **o n** **s /** **L i** **n e**  

### Projected Operating Pattern **Minimum Calculated Cycles Time**

**MANUFACTURING ASSUMPTIONS**



### Manufacturing Costs x Quantity **Process Information Gross Mark-up Costs x Quantity**  **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: R** **e f** **e r** **e n** **c e** **# 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.**P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s**

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: R** **e f** **e r** **e n** **c e** **# Part Description**  **Part Number** 

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

. V Integrated Circuit #6 IC6 NEC K3811 5XM 180703-N0402-134

. V Integrated Circuit #7 IC7 0150 30SC4M 180703-N0402-135**P i** **e c** **e /** **C y** **c l** **e /** **M a** **c h** **i n** **e T** **a c** **k T** **i m** **e /** **M a** **c h** **i n** **e /** **C y** **c l** **e "** **S e** **c o** **n d** **s "** **M u** **l t** **i p** **l i** **e r** **, I** **f R** **e q** **u i** **r e** **d f** **o r** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **( 1** **= N** **o t** **h i** **n g** **) N** **u m** **b e** **r o** **f E** **q u** **i v** **a l** **e n** **t M** **a c** **h i** **n e** **s R** **e q** **u i** **r e** **d R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r R** **e s** **u l** **t i** **n g** **C y** **c l** **e T** **i m** **e /** **P a** **r t** **" S** **e c** **. T** **o t** **a l** **N u** **m b** **e r** **o f** **D i** **r e** **c t** **O p** **e r** **a t** **o r** **s** 

### 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 (W eeks/Year): OEM Plant Location:

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

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: 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** 

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



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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

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

1 1 Assembly of PEB Bracket to SGCM/PEB 180701-N0402-01 & 180775-N0402-01 **1** 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 Into Categories with Quantity per Assembly Taken into Account

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Hybrid - Start-Stop Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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 **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** 2 2A V Bracket, PEB 180775-N0402-001-9 **1** Projection Weld T2/T3 Stamp/Form, MSMC Not Applicable Welding/Soldering Operator 

### 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 (W eeks/Year): OEM Plant Location:

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

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: 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** 

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



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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

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

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Hybrid - Start-Stop Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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 (W eeks/Year): OEM Plant Location:

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

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: 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** 

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



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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

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

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Hybrid - Start-Stop Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

1 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 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 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 all equal same value otherwise there is a computation**  **error.**



### 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 (W eeks/Year): OEM Plant Location:

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

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: 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** 

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



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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

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

**TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Mild Hybrid - Start-Stop Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **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.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment**

**(%) Total # of** 

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

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

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.24 $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**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**



## 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** 

**$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**  2A V Bracket, PEB 180775-N0402-001-9

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: R** **e f** **e r** **e n** **c e** **#** 

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



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

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

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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: R** **e f** **e r** **e n** **c e** **#** 

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



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

1A V Bolt, PEB Bracket (PEB to Mount Bracket) 180780-N0402-003 

### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

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

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$0.21**

**$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: R** **e f** **e r** **e n** **c e** **#** 

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



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

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

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account** 

**Projected Operating Pattern MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

File: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: R** **e f** **e r** **e n** **c e** **#** 

### 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.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**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

**240 15.00**  1.00 2A V Bracket, PEB 180775-N0402-001-9

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: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **#DIV/0! #DIV/0!** 

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

**#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: R** **e f** **e r** **e n** **c e** **#** 

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



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

1A V Bolt, PEB Bracket (PEB to Mount Bracket) 180780-N0402-003**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File: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: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File: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 A ssembly** 

**Level Sy**  **mbol 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 W eld Nut - Projection PEB Bracket V W eld 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-A ssembly** 



# . **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-A ssembly** 



# . **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-A ssembly** 



# . **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 A**  **round Cover V PEB Sheet Metal Wrap A**  **round Cover**



# . **2** V PEB Sheet Metal W rap Around Cover V PEB Sheet Metal W rap 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 A**  **ssy V PEB Lower Base Module Housing A**  **ssy**



# . **6 V PEB Lower Base Module Housing A**  **ssy Wash**  **V PEB Lower Base Module Housing A ssy**  **Wash**



# . **7 V PEB Lower Base Module Housing A**  **ssy Machined**  **V PEB Lower Base Module Housing A ssy**  **Machined**



# . **8 V PEB Lower Base Module Housing A**  **ssy Trim**  **V PEB Lower Base Module Housing A ssy**  **Trim**



# . **9** V PEB Lower Base Module Housing Assy Cast Material V PEB Lower Base Module Housing Assy Cast Material



# . **5 V Capacitor- A**  **sm. V Capacitor- - A**  **sm.**



# . **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 A**  **ssy V PEB Mid Base Module Housing A**  **ssy**



# . **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-W ash 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/A**  **lt Pass Through V Terminal Block PEB - Mtr/A**  **lt Pass Through**



# . **8 V Terminal Block PEB - Mtr/A**  **lt Pass Through-Weld V Terminal Block PEB - Mtr/A**  **lt Pass Through-Weld**



# . **9 V Terminal Block PEB - Mtr/A**  **lt Pass Through-Wash V Terminal Block PEB - Mtr/A**  **lt 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 A**  **node V Terminal Plate Capcitor A**  **node**



# . **8 V Terminal Plate Capcitor A**  **node-Stamp V Terminal Plate Capcitor A**  **node-Welding**



# . **9 V Terminal Plate Capcitor A**  **node-Wash V Terminal Plate Capcitor A**  **node-Wash**



# . **10 V Terminal Plate Capcitor A**  **node-Plate V Terminal Plate Capcitor A**  **node-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-A uto 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 - SURFA**  **CE MOUNT V Main Circuit Board BOTTOM SIDE - SURFA**  **CE 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 - SURFA**  **CE MOUNT V Main Circuit Board TOP SIDE - SURFA**  **CE 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-SURFA**  **CE MOUNT, ODD FORM" "V Main Circuit Board TOP-SURFA**  **CE 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 As**  **sembly 2.79**  **2.9850** 

# lb

**1 Wa**  **shed $2.79**  **2.9850** 

# lb

**1 We**  **ldment $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 $0.29**  **0.1800** 

# lb **Machined**

**1** Steel Tube **$0.29 0.1800**  

# lb

1 **As sembly**  **$0.58 0.5100**  

# lb

**1 Wa**  **shed $0.58**  **0.5100** 

# lb

**1 Machined**  **$0.58 0.5100**  

# lb

**1 Al**  **uminum - 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 As**  **sembly $0.51**  **0.4200** 

# lb

**1 Wa**  **shed $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 As**  **sembly $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 **Al uminum - 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 As**  **sembly $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 As**  **sembly $3.76**  **3.2550** 

# lb **V PEB Lower Base Module**

**1 Wa**  **shed $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 As**  **sembly $0.00**  **0.0399** 

# lb **V PEB Lower Base Module**

**1 As**  **sembly $0.00**  **0.2138** 

# lb **V PEB Lower Base Module**

**8** Commodity Pricing **$0.02 0.0033**  

# lb **V PEB Lower Base Module**

**1 As**  **sembly $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 As**  **sembly $0.10**  **0.0630** 

# lb **V PEB Lower Base Module**

**2 We**  **ldment $0.04**  **0.0500** 

# lb **V PEB Lower Base Module**

**2 Wa**  **shed $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 As**  **sembly $0.06**  **0.0200** 

# lb **V PEB Lower Base Module**

**1 We**  **ldment $0.02**  **0.0100** 

# lb **V PEB Lower Base Module**

**1 Wa**  **shed $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 As**  **sembly $0.10**  **0.0630** 

# lb **V PEB Lower Base Module**

**3 We**  **ldment $0.04**  **0.0500** 

# lb **V PEB Lower Base Module**

**3 Wa**  **shed $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 As**  **sembly $0.03**  **0.0600** 

# lb **V PEB Lower Base Module**

**4 Wa**  **shed $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 As**  **sembly $0.17**  **0.2930** 

# lb **V PEB Lower Base Module**

**1 We**  **ldment $0.15**  **0.2900** 

# lb **V PEB Lower Base Module**

**1 Wa**  **shed $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 As**  **sembly $0.20**  **0.3230** 

# lb **V PEB Lower Base Module**

**1 We**  **ldment $0.18**  **0.3200** 

# lb **V PEB Lower Base Module**

**1 Wa**  **shed $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 **As sembly**  **$0.42 0.0781**  

# lb

**1 Wa**  **shed $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 **As sembly**  **$2.06 0.1345**  

# lb

**1 Wa**  **shed $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 **As sembly**  **$0.47 0.0466**  

# lb

**1 Wa**  **shed $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 **As sembly**  **$1.79 0.0942**  

# lb

**1 Wa**  **shed $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**

**Pricing $0.00**  **0.0289** 

# lb **Commodity**

**Pricing**

**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 **As sembly**  **$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 As**  **sembly $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 As**  **sembly $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

AD2S1200W STZ-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 $0.22 0 

# lb V Main Circuit Board GD114438-2-3 Commodity Pricing 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 Wa**  **shed $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 Wa**  **shed $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 Sy**  **mbol 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 A**  **ssy 1**  **$1.88 0.7235 lb** 



# . **3 V PEB Conn Mod 8 Pin, Housing A**  **ssy 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 A**  **ssy 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 87 Commodity Pricing $0.01 V Resistors - Caps Commodity Pricing



# . 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 A**  **sm, 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 (W eeks/Year): OEM Plant Location:

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

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: 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** 

## We ekly Component Volume: Packaging Specification:

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

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

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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 COSTS MANUFACTURING RATES**  **Mild Hybrid - Start-Stop Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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**

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### 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**

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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**

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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: 2 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/21/2012

DRAFT



## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location:

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

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: 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** 

## We ekly Component Volume: Packaging Specification:

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Hybrid - Start-Stop Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

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**

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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**

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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 (W eeks/Year): OEM Plant Location:

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

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: 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** 

## We ekly Component Volume: Packaging Specification:

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Hybrid - Start-Stop Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier**

**Account**

**Cost Purchase** 

**Price/**

**Unit Purchase** 

**Price Net,**

**PIA Purchase** 

**Price Net,**

**End Item**

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

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 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. 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:

**a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error. T1 or OEM Mark-Up Rates:** 

----- ----- ----- ----- #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 all equal same value otherwise there is a computation**  **error.**



### 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 (W eeks/Year): OEM Plant Location:

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

## Annual Engine Volume (CPV): Supplier Plant Location:

**Study Case#: 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** 

## We ekly Component Volume: Packaging Specification:

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

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

**Cost T** **o t** **a l** **2 =** **T o** **t a** **l 1** **+ T** **o t** **a l** **M a** **r k** **- u** **p T** **o t** **a l** **3 =** **T o** **t a** **l 2** *******Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 

**North America**

**FOB Ship Point 47** 

**450,000**

**1**

**450,000**

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Hybrid - Start-Stop Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**TOTAL COSTS TOOLING & INVESTMENT**  

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

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Packaging**

**Cost per**

**Piece Total** 

**Amount Lump Sum** 

**Payment**

**(%) Total # of** 

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **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: R** **e f** **e r** **e n** **c e** **#** 

### 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 T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

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

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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 Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **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: R** **e f** **e r** **e n** **c e** **#** 

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



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

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

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **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!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 



### 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: R** **e f** **e r** **e n** **c e** **#** 

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



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

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

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **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: R** **e f** **e r** **e n** **c e** **#** 

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



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item

**Scrap SG&A**  **Profit ED&T** 

**R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

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

**Week Shifts./** 

**Day Hrs./** 

**Shift Hrs./** 

**Wk Wks./** 

**Yr. Hrs./** 

**Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS** 

**Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **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: R** **e f** **e r** **e n** **c e** **#** 

### 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.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

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

-

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

-

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

-

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

-

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

-

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

-



## 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: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **#DIV/0! #DIV/0!** 

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

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

-

**#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: R** **e f** **e r** **e n** **c e** **#** 

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



## Purchase Part - Commodity ( Value taken from Purchase Part Database)**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File: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: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich

(248)373-6000 Ext. 2411