Page:1 of 6 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

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

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

07 Valvetrain Subsystem

1 00 Assembly of Valvetrain Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description Part Number

Total 

Packaging 

Cost 

(Component

/ Assembly)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Technology Level: Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers

Study Case#: N0200 (N=New, 02=Multi-Air, 00 =Subcompact Vehicle Class)

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

2 01 Inlet Valves $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

3 02 Outlet Valves $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

4 03 Valve Springs $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

5 04 Spring Retainers, Cotters, Spring Seats $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

6 05 Valve Actuation Elements: Rockers, Finger Followers, Hydraulic Lash Adjusters,... $ 46.18 $ 53.67 $ 85.79 $ 185.64 $ 1.57 $ 21.96 $ 19.14 $ 5.74 $ 48.41 $ 0.10

FM Multi-Air System 01 07 05 - N0200 - 01 1 Full 1 $ 6.35 $ 2.50 $ 0.98 $ 9.83 $ 0.05 $ 0.65 $ 0.59 $ 0.25 $ 1.54 $ -

FM Solenoid Housing Assy - A 01 07 05 - N0200 - 02 1 Full 1 $ 22.69 $ 9.48 $ 9.27 $ 41.44 $ 0.25 $ 3.30 $ 2.97 $ 1.10 $ 7.62 $ 0.04

FM Solenoid Housing - B 01 07 05 - N0200 - 03 1 Full 1 $ 10.34 $ 4.91 $ 21.84 $ 37.09 $ 0.40 $ 5.15 $ 4.75 $ 1.42 $ 11.72 $ -

FM Valve Actuation Piston Assy - C 01 07 05 - N0200 - 04 8 Full 1 $ 1.69 $ 14.71 $ 26.80 $ 43.21 $ 0.39 $ 5.71 $ 4.84 $ 1.34 $ 12.29 $ 0.01

FM Solenoid Assy Cost Summation (D,E,F,G) 4 Full 1 $ 3.02 $ 21.46 $ 25.97 $ 50.45 $ 0.44 $ 6.64 $ 5.49 $ 1.48 $ 14.06 $ -

FM Oil Control Solenoid Assy - D 01 07 05 - N0200 - 05 4 Full 1 $ 0.31 $ 6.44 $ 6.69 $ 13.44 $ 0.12 $ 1.76 $ 1.45 $ 0.39 $ 3.71 $ 0.02

FM Solenoid Plunger SubAssy - E 01 07 05 - N0200 - 06 4 Full 1 $ 0.35 $ 6.74 $ 8.11 $ 15.21 $ 0.14 $ 2.03 $ 1.71 $ 0.47 $ 4.35 $ -

FM Solenoid Plunger Pin Assy & Solenoid Shell - F 01 07 05 - N0200 - 07 4 Full 1 $ 0.04 $ 5.08 $ 7.66 $ 12.77 $ 0.11 $ 1.70 $ 1.40 $ 0.38 $ 3.59 $ -

FM Electrical Assembly - G 01 07 05 - N0200 - 08 4 Full 1 $ 2.32 $ 3.20 $ 3.51 $ 9.03 $ 0.07 $ 1.15 $ 0.93 $ 0.25 $ 2.40 $ -

FM Solenoid Cover Plate Assy - H 01 07 05 - N0200 - 09 1 Full 1 $ 2.09 $ 0.62 $ 0.92 $ 3.62 $ 0.04 $ 0.51 $ 0.49 $ 0.15 $ 1.19 $ 0.02

7 06 Camshafts $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

8 08 Camshaft Phaser and/or Cam Sprockets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

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: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description Part Number

Total 

Packaging 

Cost 

(Component

/ Assembly)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Technology Level: Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers

Study Case#: N0200 (N=New, 02=Multi-Air, 00 =Subcompact Vehicle Class)

9 65 Adapters $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 70 Pipes, Hoses, Ducting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

11 75 Brackets Brackets $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ -

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

12 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

13 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

14 90 Bearings Elements Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

15 95 Vehicle Body Interface (ie Brackets, Wiring, etc) $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

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

16 99 Miscellaneous $ 24.27 $ 0.68 $ 2.32 $ 27.27 $ 0.14 $ 1.77 $ 1.64 $ 0.68 $ 4.23 $ -

Control Uprades for the Solenoid Drivers and & Temp Sensors: $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

High Side Driver - Solenoid, Valve Actuator - Cylinder #1 01 07 99 - N0200 - 01 1 Full 1

Required Hardware upgrades to Controls 

for Solenoids. ($7.50 High Side Driver 

Circuit, $2.50 Low Side Sensing Cicuit) 

($ Ratio Based on Circuit Boards)

$ 5.78 $ 0.16 $ 0.55 $ 6.49 $ 0.03 $ 0.42 $ 0.39 $ 0.16 $ 1.01 $ -

High Side Driver - Solenoid, Valve Actuator - Cylinder #2 01 07 99 - N0200 - 02 1 Full 1 Same as above $ 5.78 $ 0.16 $ 0.55 $ 6.49 $ 0.03 $ 0.42 $ 0.39 $ 0.16 $ 1.01 $ -

High Side Driver - Solenoid, Valve Actuator - Cylinder #3 01 07 99 - N0200 - 03 1 Full 1 Same as above $ 5.78 $ 0.16 $ 0.55 $ 6.49 $ 0.03 $ 0.42 $ 0.39 $ 0.16 $ 1.01 $ -

High Side Driver - Solenoid, Valve Actuator - Cylinder #4 01 07 99 - N0200 - 04 1 Full 1 Same as above $ 5.78 $ 0.16 $ 0.55 $ 6.49 $ 0.03 $ 0.42 $ 0.39 $ 0.16 $ 1.01 $ -

Low Side Driver - Temperature Sensing Monitoring Circuit 01 07 99 - N0200 - 05 1 Full 1 Same as above $ 1.16 $ 0.03 $ 0.11 $ 1.30 $ 0.01 $ 0.08 $ 0.08 $ 0.03 $ 0.20 $ -

$ 70.45 $ 54.36 $ 88.10 $ 212.91 $ 1.71 $ 23.73 $ 20.78 $ 6.42 $ 52.64 $ 0.10

Yes Complete Subsystem Quote $ 70.45 $ 54.36 $ 88.10 $ 212.91 $ 1.71 $ 23.73 $ 20.78 $ 6.42 $ 52.64 $ 0.10

Yes Complete Subsystem Quote 

(Yes/No)

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: 8/23/2012

DRAFT

Material Labor Burden End Item 

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

NEW TECHNOLOGY PACKAGE COST INFORMATION

QTY/ Subsystem

Notes

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly) Subassembly

Component

Sub-Subsystem

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Markup

Assembly

Name/Description Part Number

Total 

Packaging 

Cost 

(Component

/ Assembly)

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Total Markup 

Cost 

(Component/ 

Assembly)

Technology Level: Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers

Study Case#: N0200 (N=New, 02=Multi-Air, 00 =Subcompact Vehicle Class)

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

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: 8/23/2012

DRAFT

0

07 Valvetrain Subsystem

1 00 Assembly of Valvetrain Subsystem

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers

Study Case#: N0200 (N=New, 02=Multi-Air, 00 =Subcompact Vehicle Class)

$ - $ - $ - $ -

$ - $ - $ - $ -

$ - $ - $ - $ -

$ - $ - $ - $ -

NEW TECHNOLOGY PACKAGE COST INFORMATION

Investment

(X1000)

Tooling 

(x1000)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

2 01 Inlet Valves

3 02 Outlet Valves

4 03 Valve Springs

5 04 Spring Retainers, Cotters, Spring Seats

6 05 Valve Actuation Elements: Rockers, Finger Followers, Hydraulic Lash Adjusters,...

FM Multi-Air System 01 07 05 - N0200 - 01 1 Full 1

FM Solenoid Housing Assy - A 01 07 05 - N0200 - 02 1 Full 1

FM Solenoid Housing - B 01 07 05 - N0200 - 03 1 Full 1

FM Valve Actuation Piston Assy - C 01 07 05 - N0200 - 04 8 Full 1

FM Solenoid Assy Cost Summation (D,E,F,G) 4 Full 1

FM Oil Control Solenoid Assy - D 01 07 05 - N0200 - 05 4 Full 1

FM Solenoid Plunger SubAssy - E 01 07 05 - N0200 - 06 4 Full 1

FM Solenoid Plunger Pin Assy & Solenoid Shell - F 01 07 05 - N0200 - 07 4 Full 1

FM Electrical Assembly - G 01 07 05 - N0200 - 08 4 Full 1

FM Solenoid Cover Plate Assy - H 01 07 05 - N0200 - 09 1 Full 1

7 06 Camshafts

$ -

$ - $ - $ - $ -

$ - $ - $ - $ -

$ - $ - $ - $ -

$ - $ - $ - $ -

$ - $ - $ - $ -

$ - $ - $ - $ -

$ - $ - $ - $ -

$ - $ - $ - $ -

$ 234.14 $ - $ - $ -

$ 11.37 $ - $ - $ -

$ 49.10 $ - $ - $ -

$ 48.81 $ - $ - $ -

$ 55.50 $ - $ - $ -

$ 64.51 $ - $ - $ -

$ 17.17 $ - $ - $ -

$ 19.56 $ - $ - $ -

$ 16.37 $ - $ - $ -

$ 11.43 $ - $ - $ -

$ 4.84 $ - $ - $ -

$ - $ - $ - $ -

$ - $ - $ - $ -

8 08 Camshaft Phaser and/or Cam Sprockets $ - $ - $ - $ -

$ - $ - $ - $ -

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: 8/23/2012

DRAFT

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers

Study Case#: N0200 (N=New, 02=Multi-Air, 00 =Subcompact Vehicle Class)

9 65 Adapters

10 70 Pipes, Hoses, Ducting

11 75 Brackets

NEW TECHNOLOGY PACKAGE COST INFORMATION

Investment

(X1000)

Tooling 

(x1000)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

$ - $ - $ - $ -

$ - $ - $ - $ -

$ - $ - $ - $ -

11 75 Brackets $ - $ - $ - $ -

12 80 Boltings

13 85 Sealing Elements

14 90 Bearings Elements Misc

15 95 Vehicle Body Interface (ie Brackets, Wiring, etc)

16 99 Miscellaneous

Control Uprades for the Solenoid Drivers and & Temp Sensors:

High Side Driver - Solenoid, Valve Actuator - Cylinder #1 01 07 99 - N0200 - 01 1 Full 1

Required Hardware upgrades to Controls 

for Solenoids. ($7.50 High Side Driver 

Circuit, $2.50 Low Side Sensing Cicuit) 

($ Ratio Based on Circuit Boards)

High Side Driver - Solenoid, Valve Actuator - Cylinder #2 01 07 99 - N0200 - 02 1 Full 1 Same as above

High Side Driver - Solenoid, Valve Actuator - Cylinder #3 01 07 99 - N0200 - 03 1 Full 1 Same as above

High Side Driver - Solenoid, Valve Actuator - Cylinder #4 01 07 99 - N0200 - 04 1 Full 1 Same as above

Low Side Driver - Temperature Sensing Monitoring Circuit 01 07 99 - N0200 - 05 1 Full 1 Same as above

Yes Complete Subsystem Quote 

$ - $ - $ - $ -

$ - $ - $ - $ -

$ - $ - $ - $ -

$ - $ - $ - $ -

$ - $ - $ - $ -

$ - $ - $ - $ -

$ - $ - $ - $ -

$ - $ - $ - $ -

$ - $ - $ - $ -

$ - $ - $ - $ -

$ 31.50 $ - $ - $ -

$ - $ - $ - $ -

$ 7.50 $ - $ - $ -

$ 7.50 $ - $ - $ -

$ 7.50 $ - $ - $ -

$ 7.50 $ - $ - $ -

$ 1.50 $ - $ - $ -

$ 265.64 $ - $ - $ -

Yes Complete Subsystem Quote 

(Yes/No)

$ 265.64 $ - $ - $ -

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: 8/23/2012

DRAFT

QTY/ Subsystem

Notes

Subassembly

Component

Sub-Subsystem

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine

Item

Subsystem

NEW TECHNOLOGY PACKAGE QUOTE 

PARAMETERS

Assembly

Name/Description Part Number

Full, 

Modification, 

Differential, 

or Not 

Applicable 

Quote Level

Scaling 

Factor 

(Default =1)

Technology Level: Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers

Study Case#: N0200 (N=New, 02=Multi-Air, 00 =Subcompact Vehicle Class)

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

NEW TECHNOLOGY PACKAGE COST INFORMATION

Investment

(X1000)

Tooling 

(x1000)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

09000064810e7549.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Part Name / Description

(RED=Take Always & Green=Additions) VVT Engine Base Engine Fiat Multi-Air

Exhaust Camshaft (additional lobes 4-1ea cylinder) X

Intake Camshaft (+sensor & associated h/w) X X

Sprocket, Camshaft X X

Bolt, Sprocket X X

Bearing Caps, Camshaft X X

Bolts, Bearing Cap (10pcs-2ea cap) X X

VVT Mechanism / Module X

VVT Drivers (ECM) X

VVT Wiring Circuits (Delta 4 Versus 2 Solenoids) X

Intake Lifter Buckets (8pcs-2ea bank) X X

Timing Belt (Length & Width) / Chain (Length & Gauge) X X

Cylinder Head Processing 

Bore Lifter Buckets X X

Camshaft Line Bore X X

Valve Cover/Intake Manifold Complexity/Size Reduction

Valve Cover Size Reduction X

Part / Technology Differential Costs:

FM Multi-Air Engine Cost:

Part / Technology Presence

NET COST for FM Multi-Air System Replacement:

Notes:

[1] Multi-Air Net performance gain estimated up to +2-5% fuel economy and +2-5% CO2 reductions vs VVT Engine

[2] Multi-Air Net performance gain estimated up to +10% Hp; +15% Torque; +25% fuel economy (w/ Turbocharger); -40% unburnt HC/CO; -60% NOx vs B

[3] Multi-Air Net performance level baseline

I4 Engine QTY Total

Camp Phaser Intake $ 19.55 -1 $ (19.55)

Camp Phaser Exhaust $ 20.81 -1 $ (20.81)

VVT Control Valve $ 9.54 -2 $ (19.08)

VVT Drivers $ 7.50 -2 $ (15.00)

Wiring (2 Circuits per solenoid) $ 1.00 -2 $ (2.00)

Intake Camshaft - 8 Lobe $ 17.96 -1 $ (17.96)

Exhaust Camshaft - 8 Lobe $ 17.78 -1 $ (17.78)

VO Cam Phaser Install (Labor Install & H/W) per $ 0.79 -1 $ (0.79)

VO Cam Solenoid Install (Labor Install & H/W) per $ 0.50 -2 $ (1.00)
Drive Chain Savings (Est) (single versus dual) $ 2.00 -1 $ (2.00)

Cam Sensor + Bolt + Ass'y $ 7.24 -1 $ (7.24)

Harness, Cam Sensor ( 3 Circuits) $ 1.50 -1 $ (1.50)

Caps - Cam Shafts (5 Total) $ 0.75 -5 $ (3.75)

Bolt - Caps, Cam Shaft (10 Total) $ 0.08 -10 $ (0.80)

VO Assembly Labor - Cam Shaft $ 0.45 -1 $ (0.45)

Intake Lifter Bucket System (e.g. Spring, Retainer, Bucket) $ 1.67 -8 $ (13.36)

Cylinder Head Machining Savings (est. 25%) $ 15.42 -1 $ (15.42)

5.4 3V V8Engine

Intake Camshaft - 12 Lobe $ 25.63 1 $ 25.63

Misc

Sprocket - Timing Chain ( includes, bolt & labor) $ 2.25 1 $ 2.25

Bolt Sprocket $ 0.26 1 $ 0.26
VVT Engine Base Engine Fiat Multi-Air

 25.63

 (26.70)

 2.25

 0.26

 (4.20)

 (0.80)

 (61.23)

 (15.00)

 (2.00)

 (13.36)

 (2.00)

 (15.42)

 (10.00)

 - - (122.57)

$ 265.64 $ 265.64 $ 265.64

Associated Cost Differentials

$ 265.64 $ 265.64 $ 265.64

$ 265.64 $ 265.64 $ 143.07

[1] [2] [3]

% unburnt HC/CO; -60% NOx vs Base Engine

Other Potential MCR possibilities:

*Electronic Throttle Body Removal ($40-50)

* Intake manifold size/complexity reduction ($5-10)

10)
Page: 1 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) =48*45/(15*5) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Multi-Air System Part Number: 010705-N0200-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

1

Multi-Air System: Solenoid Housing Gasket; 

Solenoid Housing Assy; Solenoid Housing Bolts 010705-N0200-01-01 1

Position Housing Gasket to 

engine and attach Housing 

Assy, fasten w/ Bolts

OEM Assembly, Mark-up 

Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 119 3 3 1 0.000 $0.00 $38.55 $15.00 $45.00 $0.00 $0.97 $0.38 $1.35 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.35 $1.35 $0.00

2

Multi-Air System: Solenoid Cover Plate Assy; 

Solenoid Cover Plate Bolt 010705-N0200-01-02 1

Assemble Solenoid Cover Plate 

Assy to Solenoid Housing & 

fasten w/ Bolts

OEM Assembly, Mark-up 

Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 125 4 4 1 0.000 $0.00 $38.55 $15.00 $60.00 $0.00 $1.23 $0.48 $1.71 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.71 $1.71 $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

Multi-Air System: Solenoid Circuit Harness; 

Temperature Circuit Harness 010705-N0200-01-03 1

Assemble Harnesses to 

Solenoids & Temp Sensor

OEM Assembly, Mark-up 

Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 133 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.29 $0.11 $0.40 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.40 $0.40 $0.00

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

9,574

10

Costs Broken Out 

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cos

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

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

Temperature Circuit Harness Solenoids & Temp Sensor Applied @ Bottom.

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

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

1 FM Solenoid Housing Gasket 010705-N0200-01-04 1 Stamping T2/T3 Forge, SSLC PMP (Plastic Metal Plastic) Cut/Punch/Forming Operator Stamp/Form, XSS 1800 0.25 1 1 0.126 $0.70 $42.73 $24.60 $24.60 $0.09 $0.01 $0.01 $0.11 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.12 $0.12 $0.09

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

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:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) =48*45/(15*5) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Multi-Air System Part Number: 010705-N0200-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

9,574

10

Costs Broken Out 

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cos

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

31 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

32 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

33 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

34 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

35 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

36 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

37 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

38 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

39 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

40 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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

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:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) =48*45/(15*5) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Multi-Air System Part Number: 010705-N0200-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

9,574

10

Costs Broken Out 

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cos

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

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

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

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

Supplier Purchase Purchase Purchase 

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 FM Solenoid Housing Bolt 010705-N0200-01-05 9 S $0.00 $0.06 $0.00 $0.54 $0.54

2 0 $0.00 $0.00 $0.00 $0.00 $0.00

3 FM Solenoid Cover Plate Bolt 010705-N0200-01-06 18 S $0.00 $0.04 $0.00 $0.72 $0.72

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

5 FM Solenoid Harness Asm 010705-N0200-01-07 4 S $0.00 $1.00 $0.00 $4.00 $4.00

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

7 FM Temperature Harness Asm 010705-N0200-01-08 1 S $0.00 $1.00 $0.00 $1.00 $1.00

8 0 $0.00 $0.00 $0.00 $0.00 $0.00

9 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

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

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

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

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

Mark-up Calculations.

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

Supplier for Subassembly.

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

31 0 $0.00 $0.00 $0.00 $0.00 $0.00

32 0 $0.00 $0.00 $0.00 $0.00 $0.00

33 0 $0.00 $0.00 $0.00 $0.00 $0.00

34 0 $0.00 $0.00 $0.00 $0.00 $0.00

35 0 $0.00 $0.00 $0.00 $0.00 $0.00

36 0 $0.00 $0.00 $0.00 $0.00 $0.00

37 0 $0.00 $0.00 $0.00 $0.00 $0.00

38 0 $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: 4 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) =48*45/(15*5) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Multi-Air System Part Number: 010705-N0200-01 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

9,574

10

Costs Broken Out 

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cos

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

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

39 0 $0.00 $0.00 $0.00 $0.00 $0.00

40 0 $0.00 $0.00 $0.00 $0.00 $0.00

41 0 $0.00 $0.00 $0.00 $0.00 $0.00

42 0 $0.00 $0.00 $0.00 $0.00 $0.00

43 0 $0.00 $0.00 $0.00 $0.00 $0.00

44 0 $0.00 $0.00 $0.00 $0.00 $0.00

45 0 $0.00 $0.00 $0.00 $0.00 $0.00

46 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$6.35

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

Mark-up $9.84

T1 or OEM Total Manufacturing Cost: $6.35 $2.50 $0.98 $9.83 $0.00 $0.01 $0.00 $0.00 $0.01 $9.84

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.05 $0.64 $0.59 $0.25 $1.53

Base Cost Impact to Vehicle: $6.35 $2.50 $0.98 $9.83 $0.05 $0.65 $0.59 $0.25 $1.54 $11.37 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $11.37

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

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

Packaging Cost Total: $0.000

PACKAGING CALCULATIONS: 

Packaging Type: 

Part Size: 

Parts/Layer: 

Number of Layers: 

3

1

Notes: 

a) Items 1,2, & 3 mus

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: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

Multi-Air System: Solenoid Housing Gasket; 

Solenoid Housing Assy; Solenoid Housing Bolts 010705-N0200-01-01

Multi-Air System: Solenoid Cover Plate Assy; 

Solenoid Cover Plate Bolt 010705-N0200-01-02

Multi-Air System: Solenoid Circuit Harness; 

Temperature Circuit Harness 010705-N0200-01-03

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.97 $0.38 $1.35 $0.00 $0.00 $0.00 $0.00 $0.00 Position Solenoid Housing Gasket to engine and attach Solenoid Housing Assy, fasten w/ Solenoid 

Housing Bolts (9x) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 91 1 1 91 1.0 3.0

$1.23 $0.48 $1.71 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble Solenoid Cover Plate Assy to Solenoid Housing & fasten w/ Solenoid Cover Plate Bolts (18x) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 151 1 1 115 1.0 4.0

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

$0.29 $0.11 $0.40 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble Harnesses (4x) to Solenoids & (1x) Temp Sensor 5 2 10 100 47 4700 96 37.60 85% 113 31.96 27 1 1 27 1.0 1.0

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

Temperature Circuit Harness

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

FM Solenoid Housing Gasket 010705-N0200-01-04 $0.01 $0.01 $0.11 $0.00 $0.01 $0.00 $0.00 $0.01 60-200 Ton Press w/ Progressive die; operator cycle (PMP 0.4mm thick material not in RM databaseprice from Munro) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 2 1 1 2 1.0 1.0

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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

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

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

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

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

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

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

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

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

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

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

FM Solenoid Housing Bolt 010705-N0200-01-05

FM Solenoid Cover Plate Bolt 010705-N0200-01-06

FM Solenoid Harness Asm 010705-N0200-01-07

FM Temperature Harness Asm 010705-N0200-01-08

$0.54

$0.00

$0.72

$0.00

$4.00

$0.00

$1.00

$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

$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: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

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

Total

$2.50 $0.98 $9.83 $0.00 $0.01 $0.00 $0.00 $0.01

2

$9.84

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: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

Multi-Air System: Solenoid Housing Gasket; 

Solenoid Housing Assy; Solenoid Housing Bolts 010705-N0200-01-01

Multi-Air System: Solenoid Cover Plate Assy; 

Solenoid Cover Plate Bolt 010705-N0200-01-02

Multi-Air System: Solenoid Circuit Harness; 

Temperature Circuit Harness 010705-N0200-01-03

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

119 30.33 3.00

125 28.75 4.00

#DIV/0! #DIV/0! -

133 27.00 1.00 Temperature Circuit Harness

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! -

FM Solenoid Housing Gasket 010705-N0200-01-04 1800 2.00 0.25

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

FM Solenoid Housing Bolt 010705-N0200-01-05

FM Solenoid Cover Plate Bolt 010705-N0200-01-06

FM Solenoid Harness Asm 010705-N0200-01-07

FM Temperature Harness Asm 010705-N0200-01-08

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 12 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Housing Assy Part Number: 010705-N0200-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

1

Solenoid Housing Assy: Solenoid Housing; Oil 

Return Check Valve 010705-N0200-02-01 1

Assemble Oil Return Check 

Valve into Solenoid Housing - 

press & stake

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 120 1 1 1 7.129 $0.00 $38.55 $15.00 $15.00 $0.00 $0.32 $0.13 $0.45 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.45 $0.45 $0.00

2 Solenoid Housing Assy: Solenoid Check Valve 010705-N0200-02-02 1

Assemble Solenoid Check 

Valve into Solenoid Housing - 

press & stake

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 212 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.18 $0.07 $0.25 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.25 $0.25 $0.00

3

Solenoid Housing Assy: Solenoid Housing Ball 

Stops; Solenoid Housing Cup Stop 010705-N0200-02-03 1

Assemble Solenoid Housing 

Ball Stops & Cup Stop into 

Solenoid Housing - press & 

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 157 3 3 1 0.000 $0.00 $38.55 $15.00 $45.00 $0.00 $0.74 $0.29 $1.03 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.03 $1.03 $0.00

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

9,574

10

Costs Broken Out 

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cos

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

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

Stops; Solenoid Housing Cup Stop Solenoid Housing - press & 

stake

@ Bottom.

4 Solenoid Housing Assy: Rocker Pins 010705-N0200-02-04 1

Assemble Rocker Pins into 

Solenoid Housing - press to 

depth

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 240 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.08 $0.06 $0.14 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.14 $0.14 $0.00

5 Solenoid Housing Assy: Rocker Piston Bores 010705-N0200-02-05 1

Assemble Rocker Piston Bores 

into Solenoid Housing - torque

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 113 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.34 $0.13 $0.48 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.48 $0.48 $0.00

6

Solenoid Housing Assy: Rocker Pistons; Rocker 

Springs; Roller Rockers 010705-N0200-02-06 1

Assemble Rocker Pistons, 

Rocker Springs & Roller 

Rockers on Solenoid Housing

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 164 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.47 $0.18 $0.65 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.65 $0.65 $0.00

7

Solenoid Housing Assy: Pressure Relief O-Ring; 

Pressure Relief Piston; Pressure Relief Spring 010705-N0200-02-07 1

Assemble Pressure Relief ORing; Pressure Relief Piston & 

Pressure Relief Spring

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 135 4 4 1 0.000 $0.00 $38.55 $15.00 $60.00 $0.00 $1.15 $0.45 $1.59 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.59 $1.59 $0.00

8

Solenoid Housing Assy: Pressure Relief Spring 

Seat; Pressure Relief Clip 010705-N0200-02-08 1

Assemble Pressure Relief 

Spring Seat & Secure with 

Pressure Relief Clip

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 152 3 3 1 0.000 $0.00 $38.55 $15.00 $45.00 $0.00 $0.76 $0.30 $1.06 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.06 $1.06 $0.00

9 Solenoid Housing Assy: Check Valve 010705-N0200-02-09 1

Assemble Check Valve into 

Solenoid Housing Assy

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 150 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.26 $0.10 $0.36 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.36 $0.36 $0.00

10 Solenoid Housing Assy: Valve Actuation Piston 

Assy 010705-N0200-02-10 1

Assemble Valve Actuation 

Piston Assy into Solenoid 

Housing Assy & torque

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 142 3 3 1 0.000 $0.00 $38.55 $15.00 $45.00 $0.00 $0.81 $0.32 $1.13 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.13 $1.13 $0.00

11 Solenoid Housing Assy: Oil Control Solenoid 010705-N0200-02-11 1

Assemble Oil Control Solenoid 

into Solenoid Housing Ass'y

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 120 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.32 $0.13 $0.45 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.45 $0.45 $0.00

12 Solenoid Housing Assy: Oil Temp Sensor; 

Primary Oil Feed O-Ring, Center Hsg 010705-N0200-02-12 1

Assemble Oil Temp Sensor & 

Primary Oil Feed O-Ring, 

Center Hsg into Solenoid 

Housing Assy

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 157 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.25 $0.10 $0.34 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.34 $0.34 $0.00

Housing Assy

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 Solenoid Housing Assy: 010705-N0200-02-13 1

Oil / Elect Test on Solenoid 

Housing Laser Etch upon 

passing

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable Electromechanical Assembly Elec. Assembly, MHC, Base 95 1 2 1 0.000 $0.00 $36.21 $45.00 $90.00 $0.00 $0.38 $0.95 $1.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $1.33 $1.33 $0.00

15 Solenoid Housing Assy: 010705-N0200-02-14 1

Laser Etch IDs on Solenoid 

Housing

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly CNC Machining, LC 212 0.5 1 1 0.000 $0.00 $38.55 $30.38 $30.38 $0.00 $0.09 $0.14 $0.23 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.23 $0.23 $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 Rocker Piston Assy: Rocker Piston Shaft; 

Rocker Piston Cup; Rocker Piston Clip 010705-N0200-02-15 4

Assemble Rocker Piston Shaft, 

Cup & Clip into the Rocker 

Piston Assy

T1 Assembly, Mark-up Applied 

@ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base 164 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.24 $0.09 $0.33 0.00% 0.00% 0.00% 0.00% 0.00% $0.00 $0.33 $1.31 $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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Housing Assy Part Number: 010705-N0200-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

9,574

10

Costs Broken Out 

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cos

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

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

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

Pressure Relief Assy: Pressure Relief Spring 

Seat 010705-N0200-02-16 4 Grinding T2/T3 CNC Milling, MSMC Not Applicable Grinding/Polishing Operator Grinding, SS 300 0.5 1 1 0.000 $0.00 $42.14 $45.00 $45.00 $0.00 $0.07 $0.15 $0.22 0.50% 6.50% 6.00% 1.00% 14.00% $0.03 $0.25 $1.00 $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 Pressure Relief Assy: Pressure Relief Piston 010705-N0200-02-17 4 Grinding T2/T3 CNC Milling, MSMC Not Applicable Grinding/Polishing Operator Grinding, SS 300 0.5 1 1 0.000 $0.00 $42.14 $45.00 $45.00 $0.00 $0.07 $0.15 $0.22 0.50% 6.50% 6.00% 1.00% 14.00% $0.03 $0.25 $1.00 $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 Solenoid Housing Assy: Rocker Pin 010705-N0200-02-18 4 Forging T2/T3 Forge, MSMC A-Steel-4140, Bar 0.25-1" Forging Operator Forge, SS 514 0.25 1 1 0.020 $1.23 $40.18 $115.72 $115.72 $0.02 $0.02 $0.23 $0.27 0.50% 6.50% 6.00% 1.00% 14.00% $0.04 $0.31 $1.23 $0.10

6 Solenoid Housing Assy: Rocker Pin 010705-N0200-02-19 4 Grinding T2/T3 CNC Milling, MSMC Not Applicable Grinding/Polishing Operator Grinding, SS 360 0.5 1 1 0.000 $0.00 $42.14 $45.00 $45.00 $0.00 $0.06 $0.13 $0.18 0.50% 6.50% 6.00% 1.00% 14.00% $0.03 $0.21 $0.84 $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 Solenoid Housing Assy: Rocker Piston Bore 010705-N0200-02-20 4 CNC Turning T2/T3 CNC Turning, SSLC LC-Steel-1214, Bar Lathe/Turning Operator CNC Turning, SS, BF, DA 144 1 3 1 0.200 $0.62 $38.97 $20.48 $61.44 $0.12 $0.27 $0.43 $0.82 0.30% 6.00% 4.00% 0.00% 10.30% $0.08 $0.91 $3.62 $0.50

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

31 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

32 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

33 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Housing Assy Part Number: 010705-N0200-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

9,574

10

Costs Broken Out 

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cos

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

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

34 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

35 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

36 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

37 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

38 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

39 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

40 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 Solenoid Housing Assy: Rocker Pin 010705-N0502-02-21 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 8308 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.00 $0.00 $0.00

2 Solenoid Housing Assy: Rocker Pin 010705-N0502-02-22 1 Heat Treat T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC 360 0.5 1 1 0.000 $0.00 $47.72 $50.00 $50.00 $0.00 $0.07 $0.14 $0.21 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.23 $0.23 $0.00

3 Solenoid Housing Assy: Rocker Pin 010705-N0502-02-23 1 Plating T2/T3 Plate/Finish Elect., SSLC Not Applicable Plating/Coating Operator Plate Elect., SMS, LMC 800 0.25 1 1 0.000 $0.00 $40.84 $100.18 $100.18 $0.00 $0.01 $0.13 $0.14 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.15 $0.15 $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 Solenoid Housing Assy: Rocker Piston Bore 010705-N0502-02-24 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 5538 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.01 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.01 $0.01 $0.00

6 Solenoid Housing Assy: Rocker Piston Bore 010705-N0502-02-25 1 Heat Treat T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC 360 0.5 1 1 0.000 $0.00 $47.72 $50.00 $50.00 $0.00 $0.07 $0.14 $0.21 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.23 $0.23 $0.00

7 Solenoid Housing Assy: Rocker Piston Bore 010705-N0502-02-26 1 Plating T2/T3 Plate/Finish Elect., SSLC Not Applicable Plating/Coating Operator Plate Elect., SMS, LMC 800 0.25 1 1 0.000 $0.00 $40.84 $100.18 $100.18 $0.00 $0.01 $0.13 $0.14 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.15 $0.15 $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 Rocker Piston Assy: Rocker Piston Cup 010705-N0502-02-27 4 Stamp Press T2/T3 Stamp/Form, LSHC LC-Steel-1214, Bar Cut/Punch/Forming Operator Stamp/Form, Terminals 3600 0.25 1 1 0.013 $0.62 $42.73 $15.50 $15.50 $0.01 $0.00 $0.00 $0.02 0.70% 7.00% 8.00% 2.00% 17.70% $0.00 $0.02 $0.07 $0.03

13 Rocker Piston Assy: Rocker Piston Cup 010705-N0502-02-28 1 Heat Treat T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC 360 0.5 1 1 0.000 $0.00 $47.72 $50.00 $50.00 $0.00 $0.07 $0.14 $0.21 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.23 $0.23 $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 Pressure Relief Assy: Pressure Relief Piston 010705-N0502-02-29 4 Stamp Press T2/T3 Stamp/Form, LSHC LC-Steel-1214, Bar Cut/Punch/Forming Operator Stamp/Form, Terminals 3600 0.25 1 1 0.015 $0.62 $42.73 $15.50 $15.50 $0.01 $0.00 $0.00 $0.02 0.70% 7.00% 8.00% 2.00% 17.70% $0.00 $0.02 $0.08 $0.04

16 Pressure Relief Assy: Pressure Relief Piston 010705-N0502-02-30 1 Heat Treat T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC 360 0.5 1 1 0.000 $0.00 $47.72 $50.00 $50.00 $0.00 $0.07 $0.14 $0.21 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.23 $0.23 $0.00

17 Pressure Relief Assy: Pressure Relief Piston 010705-N0502-02-31 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 5538 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.01 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.01 $0.01 $0.00

18 Pressure Relief Assy: Pressure Relief Piston 010705-N0502-02-32 1 Plating T2/T3 Plate/Finish Elect., SSLC Not Applicable Plating/Coating Operator Plate Elect., SMS, LMC 800 0.25 1 1 0.000 $0.00 $40.84 $100.18 $100.18 $0.00 $0.01 $0.13 $0.14 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.15 $0.15 $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 Pressure Relief Assy: Pressure Relief Spring 

Seat 010705-N0502-02-33 4 Stamp Press T2/T3 Stamp/Form, LSHC LC-Steel-1214, Bar Cut/Punch/Forming Operator Stamp/Form, Terminals 3600 0.25 1 1 0.015 $0.62 $42.73 $15.50 $15.50 $0.01 $0.00 $0.00 $0.02 0.70% 7.00% 8.00% 2.00% 17.70% $0.00 $0.02 $0.08 $0.04

21 Pressure Relief Assy: Pressure Relief Spring 

Seat 010705-N0502-02-34 1 Heat Treat T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC 360 0.5 1 1 0.000 $0.00 $47.72 $50.00 $50.00 $0.00 $0.07 $0.14 $0.21 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.23 $0.23 $0.00

22 Pressure Relief Assy: Pressure Relief Spring 22 010705-N0502-02-35 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 5538 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.01 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.01 $0.01 $0.00 Pressure Relief Assy: Pressure Relief Spring 

Seat 010705-N0502-02-35 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 5538 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.01 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.01 $0.01 $0.00

23 Pressure Relief Assy: Pressure Relief Spring 

Seat 010705-N0502-02-36 1 Plating T2/T3 Plate/Finish Elect., SSLC Not Applicable Plating/Coating Operator Plate Elect., SMS, LMC 800 0.25 1 1 0.000 $0.00 $40.84 $100.18 $100.18 $0.00 $0.01 $0.13 $0.14 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.15 $0.15 $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: 4 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Housing Assy Part Number: 010705-N0200-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

9,574

10

Costs Broken Out 

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cos

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

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

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

Supplier 

Account 

Cost

Purchase 

Price/ 

Unit

Purchase 

Price Net, 

PIA

Purchase 

Price Net, 

End Item

1 FM Oil Return Check Valve 010705-N0502-02-37 4 S $0.00 $0.16 $0.00 $0.64 $0.64

2 0 $0.00 $0.00 $0.00 $0.00 $0.00

3 FM Solenoid Housing Ball Stop 010705-N0502-02-38 4 S $0.00 $0.04 $0.00 $0.16 $0.16

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

5 FM Solenoid Housing Cup Stop 010705-N0502-02-39 1 S $0.00 $0.02 $0.00 $0.02 $0.02

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

7 FM Rocker Spring 010705-N0502-02-40 4 S $0.00 $0.23 $0.00 $0.92 $0.92

8 0 $0.00 $0.00 $0.00 $0.00 $0.00

9 FM Roller Rocker 010705-N0502-02-41 4 S $0.00 $2.66 $0.00 $10.64 $10.64

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

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

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

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

Mark-up Calculations.

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

Supplier for Subassembly. 9 FM Roller Rocker 010705-N0502-02-41 4 S $0.00 $2.66 $0.00 $10.64 $10.64

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

11 FM Rocker Piston, Clip 010705-N0502-02-42 4 S $0.00 $0.02 $0.00 $0.08 $0.08

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

13 FM Pressure Relief O-Ring 010705-N0502-02-43 4 S $0.00 $0.07 $0.00 $0.28 $0.28

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

15 FM Pressure Relief Spring 010705-N0502-02-44 4 S $0.00 $0.04 $0.00 $0.16 $0.16

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

17 FM Pressure Relief Clip 010705-N0502-02-45 4 S $0.00 $0.02 $0.00 $0.08 $0.08

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

19 FM Check Valve 010705-N0502-02-46 8 S $0.00 $0.28 $0.00 $2.24 $2.24

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

21 FM Oil Temp Sensor 010705-N0502-02-47 1 S $0.00 $3.50 $0.00 $3.50 $3.50

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

23 FM Primary Oil Feed O-Ring, Center Hsg 010705-N0502-02-48 1 S $0.00 $0.07 $0.00 $0.07 $0.07

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

25 FM Rocker Piston, Shaft 010705-N0502-02-49 4 S $0.00 $0.80 $0.00 $3.20 $3.20

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

31 0 $0.00 $0.00 $0.00 $0.00 $0.00

32 0 $0.00 $0.00 $0.00 $0.00 $0.00

33 0 $0.00 $0.00 $0.00 $0.00 $0.00

34 0 $0.00 $0.00 $0.00 $0.00 $0.00

35 0 $0.00 $0.00 $0.00 $0.00 $0.00

36 0 $0.00 $0.00 $0.00 $0.00 $0.00

37 0 $0.00 $0.00 $0.00 $0.00 $0.00

38 0 $0.00 $0.00 $0.00 $0.00 $0.00

Supplier for Subassembly.

38 0 $0.00 $0.00 $0.00 $0.00 $0.00

39 0 $0.00 $0.00 $0.00 $0.00 $0.00

40 0 $0.00 $0.00 $0.00 $0.00 $0.00

41 0 $0.00 $0.00 $0.00 $0.00 $0.00

42 0 $0.00 $0.00 $0.00 $0.00 $0.00

43 0 $0.00 $0.00 $0.00 $0.00 $0.00

44 0 $0.00 $0.00 $0.00 $0.00 $0.00

45 0 $0.00 $0.00 $0.00 $0.00 $0.00

46 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$22.69

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Housing Assy Part Number: 010705-N0200-02 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

9,574

10

Costs Broken Out 

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cos

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

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

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

Mark-up $42.47

T1 or OEM Total Manufacturing Cost: $22.69 $9.48 $9.27 $41.44 $0.03 $0.54 $0.43 $0.04 $1.04 $42.47

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.21 $2.76 $2.55 $1.06 $6.58

Base Cost Impact to Vehicle: $22.69 $9.48 $9.27 $41.44 $0.25 $3.30 $2.97 $1.10 $7.62 $49.06 $0 $0

Packaging Cost: $0.04

Net Cost Impact to Vehicle: $49.10

3

1

Notes: 

a) Items 1,2, & 3 mus

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.041 $82,400 0.00% 2,250,000 60 5.00% $400 206 280 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: $0.041

PACKAGING CALCULATIONS: 

Packaging Type: Option #1

Part Size: 15"L x 5"W x 3"H

Parts/Layer: 28

Number of Layers: 10

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: 6 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

Solenoid Housing Assy: Solenoid Housing; Oil 

Return Check Valve 010705-N0200-02-01

Solenoid Housing Assy: Solenoid Check Valve 010705-N0200-02-02

Solenoid Housing Assy: Solenoid Housing Ball 

Stops; Solenoid Housing Cup Stop 010705-N0200-02-03

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.32 $0.13 $0.45 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble Oil Return Check Valves (4x) into Solenoid Housing and press & stake (4 place) into place w/ 

tool assist 5 2 10 100 47 4700 96 37.60 85% 113 31.96 48 1 1 30 1.0 1.0

$0.18 $0.07 $0.25 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble Solenoid Check Valve into Solenoid Housing and press & stake into place w/ tool assist 5 2 10 100 47 4700 96 37.60 85% 113 31.96 17 1 1 17 1.0 1.0

$0.74 $0.29 $1.03 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble Solenoid Housing Ball Stops (2x, 1x, 1x) & Cup Stop (1x) into Solenoid Housing - press & stake 

into place w/ tool assist 5 2 10 100 47 4700 96 37.60 85% 113 31.96 69 1 1 69 1.0 3.0

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

Stops; Solenoid Housing Cup Stop

Solenoid Housing Assy: Rocker Pins 010705-N0200-02-04

Solenoid Housing Assy: Rocker Piston Bores 010705-N0200-02-05

Solenoid Housing Assy: Rocker Pistons; Rocker 

Springs; Roller Rockers 010705-N0200-02-06

Solenoid Housing Assy: Pressure Relief O-Ring; 

Pressure Relief Piston; Pressure Relief Spring 010705-N0200-02-07

Solenoid Housing Assy: Pressure Relief Spring 

Seat; Pressure Relief Clip 010705-N0200-02-08

Solenoid Housing Assy: Check Valve 010705-N0200-02-09

Solenoid Housing Assy: Valve Actuation Piston 

Assy 010705-N0200-02-10

Solenoid Housing Assy: Oil Control Solenoid 010705-N0200-02-11

Solenoid Housing Assy: Oil Temp Sensor; 

Primary Oil Feed O-Ring, Center Hsg 010705-N0200-02-12

$0.08 $0.06 $0.14 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble Rocker Pins (4x) into Solenoid Housing - press to depth (4 place) w/ tool assist 5 2 10 100 47 4700 96 37.60 85% 113 31.96 24 1 1 15 1.0 1.0

$0.34 $0.13 $0.48 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble Rocker Piston Bores into Solenoid Housing - 4 spindle torque w/ tool assist 5 2 10 100 47 4700 96 37.60 85% 113 31.96 48 1 1 32 1.0 1.0

$0.47 $0.18 $0.65 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble Rocker Pistons (4x), Rocker Springs (4x) & Roller Rockers (4x) on Solenoid Housing 5 2 10 100 47 4700 96 37.60 85% 113 31.96 44 1 1 44 1.0 2.0

$1.15 $0.45 $1.59 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble Pressure Relief O-Rings (4x); Pressure Relief Pistons (4x) & Pressure Relief Springs (4x) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 107 1 1 107 1.0 4.0

$0.76 $0.30 $1.06 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble Pressure Relief Spring Seats (4x) & Secure with Pressure Relief Clips (4x) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 71 1 1 71 1.0 3.0

$0.26 $0.10 $0.36 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble Check Valves (8x) into Solenoid Housing Assy 5 2 10 100 47 4700 96 37.60 85% 113 31.96 24 1 1 24 1.0 1.0

$0.81 $0.32 $1.13 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble Valve Actuation Piston Assy (8x) into Solenoid Housing Assy & torque w/ power tool assist 5 2 10 100 47 4700 96 37.60 85% 113 31.96 104 1 1 76 1.0 3.0

$0.32 $0.13 $0.45 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble Oil Control Solenoids (4x) into Solenoid Housing Ass'y press to depth w/ assist 5 2 10 100 47 4700 96 37.60 85% 113 31.96 43 1 1 30 1.0 1.0

$0.25 $0.10 $0.34 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble Oil Temp Sensor (1x) & Primary Oil Feed O-Ring, Center Hsg (1x) into Solenoid Housing Assy 5 2 10 100 47 4700 96 37.60 85% 113 31.96 23 1 1 23 1.0 1.0

Solenoid Housing Assy: 010705-N0200-02-13

Solenoid Housing Assy: 010705-N0200-02-14

Rocker Piston Assy: Rocker Piston Shaft; 

Rocker Piston Cup; Rocker Piston Clip 010705-N0200-02-15

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

$0.38 $0.95 $1.33 $0.00 $0.00 $0.00 $0.00 $0.00 Oil / Electrical Test on Solenoid Housing Ass'y to calibrate solenoids vs flow performance. Wet Pressure vs electrical feedback. 

Upon passing Laser etch data onto housing body. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 34 1 1 76 1.0 2.0

$0.09 $0.14 $0.23 $0.00 $0.00 $0.00 $0.00 $0.00 Laser etch data onto housing body. Also apply part #s and logo symbol onto housing. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 9 1 1 17 1.0 1.0

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

$0.94 $0.37 $1.31 $0.00 $0.00 $0.00 $0.00 $0.00 Assemble Rocker Piston Shaft (1x), Rocker Piston Cup (1x) & Roller Piston Clip (1x) into the Rocker 

Piston Assy 5 2 10 100 47 4700 383 9.40 85% 451 7.99 22 1 1 22 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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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

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

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

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

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

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

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

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

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

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

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

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

Purchase Part - High Impact Item (Full Cost Mapping)

Pressure Relief Assy: Pressure Relief Spring 

Seat 010705-N0200-02-16

Pressure Relief Assy: Pressure Relief Piston 010705-N0200-02-17

Solenoid Housing Assy: Rocker Pin 010705-N0200-02-18

Solenoid Housing Assy: Rocker Pin 010705-N0200-02-19

Solenoid Housing Assy: Rocker Piston Bore 010705-N0200-02-20

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

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

$0.28 $0.60 $0.88 $0.00 $0.06 $0.05 $0.01 $0.12 Grind OD; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 12 1 1 12 1.0 1.0

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

$0.28 $0.60 $0.88 $0.00 $0.06 $0.05 $0.01 $0.12 Grind OD; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 12 1 1 12 1.0 1.0

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

$0.08 $0.90 $1.08 $0.01 $0.07 $0.06 $0.01 $0.15 500 Ton Hot Forge w/ automated mat'l hdlg; operator cycles 5 2 10 100 47 4700 383 9.40 85% 451 7.99 7 1 1 7 1.0 1.0

$0.23 $0.50 $0.73 $0.00 $0.05 $0.04 $0.01 $0.10 Grind OD; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 10 1 1 10 1.0 1.0

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

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

$1.08 $1.71 $3.29 $0.01 $0.20 $0.13 $0.00 $0.34 Turn OD, ID, End Faces, threads & hex end; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 75 1 1 75 1.0 3.0

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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: 8 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Solenoid Housing Assy: Rocker Pin 010705-N0502-02-21

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 30 13 1.0 1.0

Solenoid Housing Assy: Rocker Pin 010705-N0502-02-22

Solenoid Housing Assy: Rocker Pin 010705-N0502-02-23

Solenoid Housing Assy: Rocker Piston Bore 010705-N0502-02-24

Solenoid Housing Assy: Rocker Piston Bore 010705-N0502-02-25

Solenoid Housing Assy: Rocker Piston Bore 010705-N0502-02-26

Rocker Piston Assy: Rocker Piston Cup 010705-N0502-02-27

Rocker Piston Assy: Rocker Piston Cup 010705-N0502-02-28

Pressure Relief Assy: Pressure Relief Piston 010705-N0502-02-29

Pressure Relief Assy: Pressure Relief Piston 010705-N0502-02-30

Pressure Relief Assy: Pressure Relief Piston 010705-N0502-02-31

Pressure Relief Assy: Pressure Relief Piston 010705-N0502-02-32

Pressure Relief Assy: Pressure Relief Spring 

Seat 010705-N0502-02-33

Pressure Relief Assy: Pressure Relief Spring 

Seat 010705-N0502-02-34

Pressure Relief Assy: Pressure Relief Spring 010705-N0502-02-35

$0.07 $0.14 $0.21 $0.00 $0.01 $0.01 $0.00 $0.02 Heat treat rocker pin; operator load/unload & cycle 5 2 10 100 47 4700 96 37.60 85% 113 31.96 10 1 1 10 1.0 1.0

$0.01 $0.13 $0.14 $0.00 $0.01 $0.01 $0.00 $0.01 Apply plating to rocker pin; operator load/unload & cycle 5 2 10 100 47 4700 96 37.60 85% 113 31.96 9 1 2 9 1.0 1.0

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

$0.00 $0.00 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 20 13 1.0 1.0

$0.07 $0.14 $0.21 $0.00 $0.01 $0.01 $0.00 $0.02 Heat treat rocker piston bore; operator load/unload & cycle 5 2 10 100 47 4700 96 37.60 85% 113 31.96 10 1 1 10 1.0 1.0

$0.01 $0.13 $0.14 $0.00 $0.01 $0.01 $0.00 $0.01 Apply plating to rocker piston bore; operator load/unload & cycle 5 2 10 100 47 4700 96 37.60 85% 113 31.96 9 1 2 9 1.0 1.0

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

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

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

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

$0.01 $0.02 $0.06 $0.00 $0.00 $0.00 $0.00 $0.01 0-60 Ton Stamping Press w/ progressive die for Rocker Piston Cup; operator cycle controls 5 2 10 100 47 4700 383 9.40 85% 451 7.99 1 1 1 1 1.0 1.0

$0.07 $0.14 $0.21 $0.00 $0.01 $0.01 $0.00 $0.02 Heat treat rocker piston, cup; operator load/unload & cycle 5 2 10 100 47 4700 96 37.60 85% 113 31.96 10 1 1 10 1.0 1.0

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

$0.01 $0.02 $0.07 $0.00 $0.00 $0.01 $0.00 $0.01 0-60 Ton Stamping Press w/ progressive die for Pressure Relief Piston; operator cycle controls 5 2 10 100 47 4700 383 9.40 85% 451 7.99 1 1 1 1 1.0 1.0

$0.07 $0.14 $0.21 $0.00 $0.01 $0.01 $0.00 $0.02 Heat treat pressure relief piston; operator load/unload & cycle 5 2 10 100 47 4700 96 37.60 85% 113 31.96 10 1 1 10 1.0 1.0

$0.00 $0.00 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 20 13 1.0 1.0

$0.01 $0.13 $0.14 $0.00 $0.01 $0.01 $0.00 $0.01 Apply plating to pressure relief piston; operator load/unload & cycle 5 2 10 100 47 4700 96 37.60 85% 113 31.96 9 1 2 9 1.0 1.0

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

$0.01 $0.02 $0.07 $0.00 $0.00 $0.01 $0.00 $0.01 0-60 Ton Stamping Press w/ progressive die for Pressure Relief Piston; operator cycle controls 5 2 10 100 47 4700 383 9.40 85% 451 7.99 1 1 1 1 1.0 1.0

$0.07 $0.14 $0.21 $0.00 $0.01 $0.01 $0.00 $0.02 Heat treat pressure relief piston; operator load/unload & cycle 5 2 10 100 47 4700 96 37.60 85% 113 31.96 10 1 1 10 1.0 1.0

$0.00 $0.00 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 20 13 1.0 1.0 Pressure Relief Assy: Pressure Relief Spring 

Seat 010705-N0502-02-35

Pressure Relief Assy: Pressure Relief Spring 

Seat 010705-N0502-02-36

$0.00 $0.00 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 20 13 1.0 1.0

$0.01 $0.13 $0.14 $0.00 $0.01 $0.01 $0.00 $0.01 Apply plating to pressure relief spring seat; operator load/unload & cycle 5 2 10 100 47 4700 96 37.60 85% 113 31.96 9 1 2 9 1.0 1.0

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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: 9 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

FM Oil Return Check Valve 010705-N0502-02-37

FM Solenoid Housing Ball Stop 010705-N0502-02-38

FM Solenoid Housing Cup Stop 010705-N0502-02-39

FM Rocker Spring 010705-N0502-02-40

FM Roller Rocker 010705-N0502-02-41

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.64

$0.00

$0.16

$0.00

$0.02

$0.00

$0.92

$0.00

FM Roller Rocker 010705-N0502-02-41 $10.64

FM Rocker Piston, Clip 010705-N0502-02-42

FM Pressure Relief O-Ring 010705-N0502-02-43

FM Pressure Relief Spring 010705-N0502-02-44

FM Pressure Relief Clip 010705-N0502-02-45

FM Check Valve 010705-N0502-02-46

FM Oil Temp Sensor 010705-N0502-02-47

FM Primary Oil Feed O-Ring, Center Hsg 010705-N0502-02-48

FM Rocker Piston, Shaft 010705-N0502-02-49

$10.64

$0.00

$0.08

$0.00

$0.28

$0.00

$0.16

$0.00

$0.08

$0.00

$2.24

$0.00

$3.50

$0.00

$0.07

$0.00

$3.20

$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

$9.48 $9.27 $41.44 $0.03 $0.54 $0.43 $0.04 $1.04

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$42.47

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: 11 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

Solenoid Housing Assy: Solenoid Housing; Oil 

Return Check Valve 010705-N0200-02-01

Solenoid Housing Assy: Solenoid Check Valve 010705-N0200-02-02

Solenoid Housing Assy: Solenoid Housing Ball 

Stops; Solenoid Housing Cup Stop 010705-N0200-02-03

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

120 30.00 1.00

212 17.00 1.00

157 23.00 3.00 Stops; Solenoid Housing Cup Stop

Solenoid Housing Assy: Rocker Pins 010705-N0200-02-04

Solenoid Housing Assy: Rocker Piston Bores 010705-N0200-02-05

Solenoid Housing Assy: Rocker Pistons; Rocker 

Springs; Roller Rockers 010705-N0200-02-06

Solenoid Housing Assy: Pressure Relief O-Ring; 

Pressure Relief Piston; Pressure Relief Spring 010705-N0200-02-07

Solenoid Housing Assy: Pressure Relief Spring 

Seat; Pressure Relief Clip 010705-N0200-02-08

Solenoid Housing Assy: Check Valve 010705-N0200-02-09

Solenoid Housing Assy: Valve Actuation Piston 

Assy 010705-N0200-02-10

Solenoid Housing Assy: Oil Control Solenoid 010705-N0200-02-11

Solenoid Housing Assy: Oil Temp Sensor; 

Primary Oil Feed O-Ring, Center Hsg 010705-N0200-02-12

240 15.00 0.50

113 32.00 1.00

164 22.00 2.00

135 26.75 4.00

152 23.67 3.00

150 24.00 1.00

142 25.33 3.00

120 30.00 1.00

157 23.00 1.00

Solenoid Housing Assy: 010705-N0200-02-13

Solenoid Housing Assy: 010705-N0200-02-14

Rocker Piston Assy: Rocker Piston Shaft; 

Rocker Piston Cup; Rocker Piston Clip 010705-N0200-02-15

#DIV/0! #DIV/0! -

95 38.00 1.00

212 17.00 0.50

#DIV/0! #DIV/0! -

164 22.00 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: 12 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

Pressure Relief Assy: Pressure Relief Spring 

Seat 010705-N0200-02-16

Pressure Relief Assy: Pressure Relief Piston 010705-N0200-02-17

Solenoid Housing Assy: Rocker Pin 010705-N0200-02-18

Solenoid Housing Assy: Rocker Pin 010705-N0200-02-19

Solenoid Housing Assy: Rocker Piston Bore 010705-N0200-02-20

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

300 12.00 0.50

#DIV/0! #DIV/0! -

300 12.00 0.50

#DIV/0! #DIV/0! -

514 7.00 0.25

360 10.00 0.50

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

144 25.00 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! -

#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: 13 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

Solenoid Housing Assy: Rocker Pin 010705-N0502-02-21

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

8308 0.43 0.25

Solenoid Housing Assy: Rocker Pin 010705-N0502-02-22

Solenoid Housing Assy: Rocker Pin 010705-N0502-02-23

Solenoid Housing Assy: Rocker Piston Bore 010705-N0502-02-24

Solenoid Housing Assy: Rocker Piston Bore 010705-N0502-02-25

Solenoid Housing Assy: Rocker Piston Bore 010705-N0502-02-26

Rocker Piston Assy: Rocker Piston Cup 010705-N0502-02-27

Rocker Piston Assy: Rocker Piston Cup 010705-N0502-02-28

Pressure Relief Assy: Pressure Relief Piston 010705-N0502-02-29

Pressure Relief Assy: Pressure Relief Piston 010705-N0502-02-30

Pressure Relief Assy: Pressure Relief Piston 010705-N0502-02-31

Pressure Relief Assy: Pressure Relief Piston 010705-N0502-02-32

Pressure Relief Assy: Pressure Relief Spring 

Seat 010705-N0502-02-33

Pressure Relief Assy: Pressure Relief Spring 

Seat 010705-N0502-02-34

Pressure Relief Assy: Pressure Relief Spring 010705-N0502-02-35

360 10.00 0.50

800 4.50 0.25

#DIV/0! #DIV/0! -

5538 0.65 0.25

360 10.00 0.50

800 4.50 0.25

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

3600 1.00 0.25

360 10.00 0.50

#DIV/0! #DIV/0! -

3600 1.00 0.25

360 10.00 0.50

5538 0.65 0.25

800 4.50 0.25

#DIV/0! #DIV/0! -

3600 1.00 0.25

360 10.00 0.50

5538 0.65 0.25 Pressure Relief Assy: Pressure Relief Spring 

Seat 010705-N0502-02-35

Pressure Relief Assy: Pressure Relief Spring 

Seat 010705-N0502-02-36

5538 0.65 0.25

800 4.50 0.25

#DIV/0! #DIV/0! -

#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: 14 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

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

FM Oil Return Check Valve 010705-N0502-02-37

FM Solenoid Housing Ball Stop 010705-N0502-02-38

FM Solenoid Housing Cup Stop 010705-N0502-02-39

FM Rocker Spring 010705-N0502-02-40

FM Roller Rocker 010705-N0502-02-41

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

FM Roller Rocker 010705-N0502-02-41

FM Rocker Piston, Clip 010705-N0502-02-42

FM Pressure Relief O-Ring 010705-N0502-02-43

FM Pressure Relief Spring 010705-N0502-02-44

FM Pressure Relief Clip 010705-N0502-02-45

FM Check Valve 010705-N0502-02-46

FM Oil Temp Sensor 010705-N0502-02-47

FM Primary Oil Feed O-Ring, Center Hsg 010705-N0502-02-48

FM Rocker Piston, Shaft 010705-N0502-02-49

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 15 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Housing Assy Part Number: 010705-N0200-03 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

1 Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-01 1 Forging T2/T3 Forge, MSMC Aluminum-6062, Bar Forging Operator Forge, SS 176 1 2 1 7.129 $1.45 $40.18 $115.72 $231.44 $10.34 $0.23 $1.32 $11.88 0.50% 6.50% 6.00% 1.00% 14.00% $1.66 $13.55 $13.55 $10.34

2 Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-02 1 Trim Press T2/T3 Stamp/Form, SSLC Not Applicable Cut/Punch/Forming Operator Trim Press, SS 257 0.5 1 1 0.000 $0.00 $42.73 $21.78 $21.78 $0.00 $0.08 $0.08 $0.17 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.19 $0.19 $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 Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-03 1 CNC Horiz Machining T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MHC 113 3 11 1 0.000 $0.00 $36.98 $53.25 $585.75 $0.00 $0.98 $5.16 $6.14 0.50% 6.50% 6.00% 1.00% 14.00% $0.86 $7.00 $7.00 $0.00

5 Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-04 1 CNC Horiz Machining T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MHC 127 1 4 1 0.000 $0.00 $36.98 $53.25 $213.00 $0.00 $0.29 $1.67 $1.96 0.50% 6.50% 6.00% 1.00% 14.00% $0.27 $2.24 $2.24 $0.00

6 Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-05 1 CNC Horiz Machining T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MHC 126 2 6 1 0.000 $0.00 $36.98 $53.25 $319.50 $0.00 $0.59 $2.54 $3.13 0.50% 6.50% 6.00% 1.00% 14.00% $0.44 $3.57 $3.57 $0.00

7 Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-06 1 CNC Horiz Machining T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MHC 148 1 3 1 0.000 $0.00 $36.98 $53.25 $159.75 $0.00 $0.25 $1.08 $1.33 0.50% 6.50% 6.00% 1.00% 14.00% $0.19 $1.52 $1.52 $0.00

8 Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-07 1 CNC Horiz Machining T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MHC 116 2 8 1 0.000 $0.00 $36.98 $53.25 $426.00 $0.00 $0.64 $3.68 $4.32 0.50% 6.50% 6.00% 1.00% 14.00% $0.61 $4.93 $4.93 $0.00

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

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

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

8 Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-07 1 CNC Horiz Machining T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MHC 116 2 8 1 0.000 $0.00 $36.98 $53.25 $426.00 $0.00 $0.64 $3.68 $4.32 0.50% 6.50% 6.00% 1.00% 14.00% $0.61 $4.93 $4.93 $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 Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-08 1

Air / Elect Test on Solenoid 

Hsg. Stamp part upon passing. T2/T3 Elect. Assembly, SSLC Not Applicable Electromechanical Assembly Elec. Assembly, MC, Base 150 0.5 1 1 0.000 $0.00 $36.21 $30.00 $30.00 $0.00 $0.12 $0.20 $0.32 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.35 $0.35 $0.00

11 Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-09 1

Laser Etch IDs on Solenoid 

Housing T2/T3 CNC Milling, SSLC Not Applicable General Assembly CNC Machining, LC 450 0.5 1 1 0.000 $0.00 $38.55 $30.38 $30.38 $0.00 $0.04 $0.07 $0.11 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.12 $0.12 $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 Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-10 1 CNC Submerged Hydro Deburr T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MC 124 2 6 1 0.000 $0.00 $36.98 $45.37 $272.22 $0.00 $0.60 $2.20 $2.80 0.50% 6.50% 6.00% 1.00% 14.00% $0.39 $3.19 $3.19 $0.00

2 Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-11 1 CNC Submerged Hydro Deburr T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MC 127 1 2 1 0.000 $0.00 $36.98 $45.37 $90.74 $0.00 $0.29 $0.71 $1.00 0.50% 6.50% 6.00% 1.00% 14.00% $0.14 $1.14 $1.14 $0.00

3 Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-12 1 CNC Submerged Hydro Deburr T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MC 126 1 3 1 0.000 $0.00 $36.98 $45.37 $136.11 $0.00 $0.29 $1.08 $1.38 0.50% 6.50% 6.00% 1.00% 14.00% $0.19 $1.57 $1.57 $0.00

4 Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-13 1 CNC Submerged Hydro Deburr T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MC 197 1 2 1 0.000 $0.00 $36.98 $45.37 $90.74 $0.00 $0.19 $0.46 $0.65 0.50% 6.50% 6.00% 1.00% 14.00% $0.09 $0.74 $0.74 $0.00

5 Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-14 1 CNC Submerged Hydro Deburr T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, MC 116 1 4 1 0.000 $0.00 $36.98 $45.37 $181.48 $0.00 $0.32 $1.57 $1.89 0.50% 6.50% 6.00% 1.00% 14.00% $0.26 $2.15 $2.15 $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

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Housing Assy Part Number: 010705-N0200-03 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

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

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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

31 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

32 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

33 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

34 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

35 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

36 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

37 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

38 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

39 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

40 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-15 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 8308 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.00 $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

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Housing Assy Part Number: 010705-N0200-03 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

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

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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

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

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

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

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

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

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

Mark-up Calculations.

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

Supplier for Subassembly.

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

31 0 $0.00 $0.00 $0.00 $0.00 $0.00

32 0 $0.00 $0.00 $0.00 $0.00 $0.00

33 0 $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: 4 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Housing Assy Part Number: 010705-N0200-03 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

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

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

34 0 $0.00 $0.00 $0.00 $0.00 $0.00

35 0 $0.00 $0.00 $0.00 $0.00 $0.00

36 0 $0.00 $0.00 $0.00 $0.00 $0.00

37 0 $0.00 $0.00 $0.00 $0.00 $0.00

38 0 $0.00 $0.00 $0.00 $0.00 $0.00

39 0 $0.00 $0.00 $0.00 $0.00 $0.00

40 0 $0.00 $0.00 $0.00 $0.00 $0.00

41 0 $0.00 $0.00 $0.00 $0.00 $0.00

42 0 $0.00 $0.00 $0.00 $0.00 $0.00

43 0 $0.00 $0.00 $0.00 $0.00 $0.00

44 0 $0.00 $0.00 $0.00 $0.00 $0.00

45 0 $0.00 $0.00 $0.00 $0.00 $0.00

46 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$10.34

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

Mark-up $42.26

T1 or OEM Total Manufacturing Cost: $10.34 $4.91 $21.84 $37.09 $0.18 $2.41 $2.21 $0.36 $5.17 $42.26

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.21 $2.75 $2.54 $1.06 $6.55

Base Cost Impact to Vehicle: $10.34 $4.91 $21.84 $37.09 $0.40 $5.15 $4.75 $1.42 $11.72 $48.81 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $48.81

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

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

Packaging 

Cost per 

Piece

Tier Pad 

Price Per

Tier Pads 

Pallet/Rack

Divider Pads, 

Price Per

Divider Pads 

Pallet/Rack

Other #1 

Packaging 

Price Per

Other #1 

Pads 

Pallet/Rack

Other #2 

Packaging 

Price Per

Other #2 

Pads 

Pallet/Rack

Other #3 

Packaging, 

Price Per

Other #3 

Pads 

Pallet/Rack

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

3

1

Notes: 

a) Items 1,2, & 3 mus

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.

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

Packaging Cost Total: $0.000

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

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

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

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

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

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

File: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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Housing Assy Part Number: 010705-N0200-03 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

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

9,574

10

North America

North America

FOB Ship Point

47

450,000

1

450,000

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

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

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-01

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-02

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-03

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-04

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-05

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-06

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-07

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.23 $1.32 $11.88 $0.06 $0.77 $0.71 $0.12 $1.66 500 Ton Hot Forge w/ automated mat'l hdlg; operator cycles 5 2 10 100 47 4700 96 37.60 85% 113 31.96 9 1 1 41 1.0 2.0

$0.08 $0.08 $0.17 $0.00 $0.01 $0.01 $0.00 $0.02 60-200 Ton Trim Press; operator load/unload & cycle 5 2 10 100 47 4700 96 37.60 85% 113 31.96 14 1 1 14 1.0 1.0

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

$0.98 $5.16 $6.14 $0.03 $0.40 $0.37 $0.06 $0.86 CNC Horiz Machining of Solenoid Hsg features from the "Top Direction"; operator load/unload & cycles 5 2 10 100 47 4700 96 37.60 85% 113 31.96 349 1 1 349 1.0 11.0

$0.29 $1.67 $1.96 $0.01 $0.13 $0.12 $0.02 $0.27 CNC Horiz Machining of Solenoid Hsg features from the "Rocker Arm Direction"; operator load/unload & 

cycles 5 2 10 100 47 4700 96 37.60 85% 113 31.96 113 1 1 113 1.0 4.0

$0.59 $2.54 $3.13 $0.02 $0.20 $0.19 $0.03 $0.44 CNC Horiz Machining of Solenoid Hsg features from the "Solenoid Holes Direction"; operator load/unload 

& cycles 5 2 10 100 47 4700 96 37.60 85% 113 31.96 172 1 1 172 1.0 6.0

$0.25 $1.08 $1.33 $0.01 $0.09 $0.08 $0.01 $0.19 CNC Horiz Machining of Solenoid Hsg features from the "Gun Drill from BOTH Directions"; operator 

load/unload & cycles 5 2 10 100 47 4700 96 37.60 85% 113 31.96 73 1 1 73 1.0 3.0

$0.64 $3.68 $4.32 $0.02 $0.28 $0.26 $0.04 $0.61 CNC Horiz Machining of Solenoid Hsg features from the "Bottom Surface Direction"; operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 249 1 1 249 1.0 8.0

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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

Projected Operating Pattern Minimum Calculated Cycles Time 

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-07

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-08

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-09

Purchase Part - High Impact Item (Full Cost Mapping)

$0.64 $3.68 $4.32 $0.02 $0.28 $0.26 $0.04 $0.61 CNC Horiz Machining of Solenoid Hsg features from the "Bottom Surface Direction"; operator load/unload 

& cycles 5 2 10 100 47 4700 96 37.60 85% 113 31.96 249 1 1 249 1.0 8.0

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

$0.12 $0.20 $0.32 $0.00 $0.02 $0.01 $0.00 $0.03 Air / Elect Test on Solenoid housing. Pressure vs electrical feedback. Stamp housing body upon passing. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 16 1 1 24 1.0 1.0

$0.04 $0.07 $0.11 $0.00 $0.01 $0.00 $0.00 $0.01 Stamp solenoid housing body to acknowledge part passing. 5 2 10 100 47 4700 96 37.60 85% 113 31.96 8 1 1 8 1.0 1.0

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-10

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-11

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-12

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-13

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-14

$0.60 $2.20 $2.80 $0.01 $0.18 $0.17 $0.03 $0.39 CNC Horiz Machining of Solenoid Hsg features from the "Top Direction"; operator load/unload & cycles 5 2 10 100 47 4700 96 37.60 85% 113 31.96 349 1 1 175 1.0 6.0

$0.29 $0.71 $1.00 $0.01 $0.07 $0.06 $0.01 $0.14 CNC Horiz Machining of Solenoid Hsg features from the "Rocker Arm Direction"; operator load/unload & 

cycles 5 2 10 100 47 4700 96 37.60 85% 113 31.96 113 1 1 57 1.0 2.0

$0.29 $1.08 $1.38 $0.01 $0.09 $0.08 $0.01 $0.19 CNC Horiz Machining of Solenoid Hsg features from the "Solenoid Holes Direction"; operator load/unload 

& cycles 5 2 10 100 47 4700 96 37.60 85% 113 31.96 172 1 1 86 1.0 3.0

$0.19 $0.46 $0.65 $0.00 $0.04 $0.04 $0.01 $0.09 CNC Horiz Machining of Solenoid Hsg features from the "Gun Drill from BOTH Directions"; operator 

load/unload & cycles 5 2 10 100 47 4700 96 37.60 85% 113 31.96 73 1 1 37 1.0 2.0

$0.32 $1.57 $1.89 $0.01 $0.12 $0.11 $0.02 $0.26 CNC Horiz Machining of Solenoid Hsg features from the "Bottom Surface Direction"; operator load/unload 

& cycles 5 2 10 100 47 4700 96 37.60 85% 113 31.96 249 1 1 125 1.0 4.0

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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

Projected Operating Pattern 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)

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-15

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 30 13 1.0 1.0

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

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

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

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

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

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

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

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

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

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

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

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

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

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

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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

Projected Operating Pattern 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 - Commodity ( Value taken from Purchase Part Database)

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

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

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

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

$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

$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: 9 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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

Projected Operating Pattern Minimum Calculated Cycles Time 

$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

$4.91 $21.84 $37.09 $0.18 $2.41 $2.21 $0.36 $5.17

$42.26

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: 10 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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

Projected Operating Pattern 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: 11 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-01

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-02

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-03

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-04

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-05

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-06

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-07

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

176 20.50 1.00

257 14.00 0.50

#DIV/0! #DIV/0! -

113 31.73 3.00

127 28.25 1.00

126 28.67 2.00

148 24.33 1.00

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-07 116 31.13 2.00

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-08

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-09

Purchase Part - High Impact Item (Full Cost Mapping)

116 31.13 2.00

#DIV/0! #DIV/0! -

150 24.00 0.50

450 8.00 0.50

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-10

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-11

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-12

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-13

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-14

124 29.08 2.00

127 28.25 1.00

126 28.67 1.00

197 18.25 1.00

116 31.13 1.00

#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: 12 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

Solenoid Housing Assy: Solenoid Housing 010705-N0200-03-15

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

8308 0.43 0.25

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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: 13 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

#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: 14 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 15 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Valve Actuation Piston Assy Part Number: 010705-N0200-04 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS Manufacturing C

Costs Broken O

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

76,596

10

North America

North America

FOB Ship Point

47

450,000

8

3,600,000

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

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

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

Valve Actuation Piston Assy: Valve Actuation 

Piston, Cap; Valve Actuation Piston, Cap 010705-N0200-04-01 1

Assemble Valve Actuation 

Piston, Cap with Valve 

Actuation Piston, Cap

T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 1108 4 4 1 0.000 $0.00 $38.55 $15.00 $60.00 $0.00 $0.14 $0.05 $0.19 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.21 $0.21 $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

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin; Valve Actuation Piston, Spring 

Guide

010705-N0200-04-02 1

Assemble Valve Actuation 

Piston, Long Pin to Valve 

Actuation Piston, Spring Guide

T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 900 3 3 1 0.000 $0.00 $38.55 $15.00 $45.00 $0.00 $0.13 $0.05 $0.18 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.20 $0.20 $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

Valve Actuation Piston Assy: Valve Actuation 

Piston, Spring; Valve Actuation Piston, Housing; 

Valve Actuation Piston, Short Pin; Valve 

Actuation Piston, Yellow O-Ring; Valve 

Actuation Piston, Black O-Ring

010705-N0200-04-03 1

Assemble Valve Actuation 

Piston, Spring; Housing & Short 

Pin with Valve Yellow and 

Black O-Rings

T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 933 3 7 1 0.000 $0.00 $38.55 $15.00 $105.00 $0.00 $0.12 $0.11 $0.24 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.26 $0.26 $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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Valve Actuation Piston Assy Part Number: 010705-N0200-04 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS Manufacturing C

Costs Broken O

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

76,596

10

North America

North America

FOB Ship Point

47

450,000

8

3,600,000

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

29 Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-04 1 Forging T2/T3 Forge, MSMC LC-Steel-1214, Bar Forging Operator Forge, SS 1200 1 2 1 0.010 $0.62 $40.18 $115.72 $231.44 $0.01 $0.03 $0.19 $0.23 0.50% 6.50% 6.00% 1.00% 14.00% $0.03 $0.27 $0.27 $0.01

30 Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-05 1 Grinding T2/T3 CNC Milling, MSMC Not Applicable Grinding/Polishing Operator Grinding, SS 982 1 3 1 0.000 $0.00 $42.14 $45.00 $135.00 $0.00 $0.04 $0.14 $0.18 0.50% 6.50% 6.00% 1.00% 14.00% $0.03 $0.21 $0.21 $0.00

31 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

32 Valve Actuation Piston Assy: Valve Actuation 

Piston, Housing 010705-N0200-04-06 1 Grinding T2/T3 CNC Milling, MSMC Not Applicable Grinding/Polishing Operator Grinding, SS 900 1 3 1 0.000 $0.00 $42.14 $45.00 $135.00 $0.00 $0.05 $0.15 $0.20 0.50% 6.50% 6.00% 1.00% 14.00% $0.03 $0.22 $0.22 $0.00

33 Valve Actuation Piston Assy: Valve Actuation 

Piston, Housing 010705-N0200-04-07 1 CNC Turning T2/T3 CNC Turning, SSLC Not Applicable Lathe/Turning Operator CNC Turning, SS, BF, DA 914 16 32 1 0.180 $0.00 $38.97 $20.48 $655.36 $0.00 $0.68 $0.72 $1.40 0.30% 6.00% 4.00% 0.00% 10.30% $0.14 $1.54 $1.54 $0.00

34 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

35 Valve Actuation Piston Assy: Valve Actuation 

Piston, Cap 010705-N0200-04-08 1 CNC Turning T2/T3 CNC Turning, SSLC Not Applicable Lathe/Turning Operator CNC Turning, SS, BF, DA 900 3 6 1 0.000 $0.00 $38.97 $20.48 $122.88 $0.00 $0.13 $0.14 $0.27 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.29 $0.29 $0.00

36 Valve Actuation Piston Assy: Valve Actuation 

Piston, Cap 010705-N0200-04-09 1 Forging T2/T3 Forge, MSMC LC-Steel-1214, Bar Forging Operator Forge, SS 1080 1 3 1 0.020 $1.00 $40.18 $115.72 $347.16 $0.02 $0.04 $0.32 $0.38 0.50% 6.50% 6.00% 1.00% 14.00% $0.05 $0.43 $0.43 $0.02

37 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

38 Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-10 1 CNC Turning T2/T3 CNC Turning, SSLC Not Applicable Lathe/Turning Operator CNC Turning, SS, BF, DA 1108 2 4 1 0.000 $0.73 $38.97 $20.48 $81.92 $0.00 $0.07 $0.07 $0.14 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.16 $0.16 $0.00

39 Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-11 1 Forging T2/T3 Forge, MSMC LC-Steel-1214, Bar Forging Operator Forge, SS 1029 2 4 1 0.030 $0.62 $40.18 $115.72 $462.88 $0.02 $0.08 $0.45 $0.55 0.50% 6.50% 6.00% 1.00% 14.00% $0.08 $0.62 $0.62 $0.02

40 Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-12 1 Grinding T2/T3 CNC Milling, MSMC Not Applicable Grinding/Polishing Operator Grinding, SS 900 1 3 1 0.000 $0.00 $42.14 $45.00 $135.00 $0.00 $0.05 $0.15 $0.20 0.50% 6.50% 6.00% 1.00% 14.00% $0.03 $0.22 $0.22 $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

Valve Actuation Piston Assy: Valve Actuation 

Piston, Cap 010705-N0200-04-13 1 Heat Treat T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC 1080 1 3 1 0.000 $0.00 $47.72 $50.00 $150.00 $0.00 $0.04 $0.14 $0.18 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.20 $0.20 $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

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Valve Actuation Piston Assy Part Number: 010705-N0200-04 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS Manufacturing C

Costs Broken O

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

76,596

10

North America

North America

FOB Ship Point

47

450,000

8

3,600,000

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

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

5

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-14 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 8308 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.00 $0.00 $0.00

6

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-15 1 Heat Treat T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC 1080 1 3 1 0.000 $0.00 $47.72 $50.00 $150.00 $0.00 $0.04 $0.14 $0.18 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.20 $0.20 $0.00

7

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-16 1 Plating T2/T3 Plate/Finish Elect., SSLC Not Applicable Plating/Coating Operator Plate Elect., SMS, LMC 800 1 1 1 0.000 $0.00 $40.84 $100.18 $100.18 $0.00 $0.05 $0.13 $0.18 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.19 $0.19 $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

Valve Actuation Piston Assy: Valve Actuation 

Piston, Spring Guide 010705-N0200-04-17 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 13846 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.00 $0.00 $0.00

10 Valve Actuation Piston Assy: Valve Actuation 

Piston, Spring Guide 010705-N0200-04-18 1 Stamp Press T2/T3 Stamp/Form, LSHC LC-Steel-1214, Bar Cut/Punch/Forming Operator Stamp/Form, Terminals 3600 0.25 1 1 0.011 $0.62 $42.73 $15.50 $15.50 $0.01 $0.00 $0.00 $0.01 0.70% 7.00% 8.00% 2.00% 17.70% $0.00 $0.02 $0.02 $0.01

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 Valve Actuation Piston Assy: Valve Actuation 

Piston, Housing 010705-N0200-04-19 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 13846 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.00 $0.00 $0.00

13 Valve Actuation Piston Assy: Valve Actuation 

Piston, Housing 010705-N0200-04-20 1 Heat Treat T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC 1080 1 3 1 0.000 $0.00 $47.72 $50.00 $150.00 $0.00 $0.04 $0.14 $0.18 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.20 $0.20 $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 Valve Actuation Piston Assy: Valve Actuation 

Piston, Short Pin 010705-N0200-04-21 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 8308 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.00 $0.00 $0.00

16 Valve Actuation Piston Assy: Valve Actuation 

Piston, Short Pin 010705-N0200-04-22 1 Heat Treat T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC 1080 1 3 1 0.000 $0.00 $47.72 $50.00 $150.00 $0.00 $0.04 $0.14 $0.18 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.20 $0.20 $0.00

17 Valve Actuation Piston Assy: Valve Actuation 

Piston, Short Pin 010705-N0200-04-23 1 Plating T2/T3 Plate/Finish Elect., SSLC Not Applicable Plating/Coating Operator Plate Elect., SMS, LMC 900 1 1 1 0.000 $0.00 $40.84 $100.18 $100.18 $0.00 $0.05 $0.11 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.17 $0.17 $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

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 FM Valve Actuation Piston, Clip 010705-N0200-04-24 1 (qtys applied on CMAT) S $0.00 $0.02 $0.00 $0.02 $0.02 "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub2 0 $0.00 $0.00 $0.00 $0.00 $0.00

3 FM Valve Actuation Piston, Spring 010705-N0200-04-25 1 (qtys applied on CMAT) S $0.00 $0.01 $0.00 $0.01 $0.01

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

5 FM Valve Actuation Piston, Yellow O-Ring 010705-N0200-04-26 1 (qtys applied on CMAT) S $0.00 $0.07 $0.00 $0.07 $0.07

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

7 FM Valve Actuation Piston, Black O-Ring 010705-N0200-04-27 1 (qtys applied on CMAT) S $0.00 $0.06 $0.00 $0.06 $0.06

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

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

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

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

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

Mark-up Calculations.

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

Supplier for Subassembly.

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Valve Actuation Piston Assy Part Number: 010705-N0200-04 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS Manufacturing C

Costs Broken O

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

76,596

10

North America

North America

FOB Ship Point

47

450,000

8

3,600,000

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

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

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

31 0 $0.00 $0.00 $0.00 $0.00 $0.00

32 0 $0.00 $0.00 $0.00 $0.00 $0.00

33 0 $0.00 $0.00 $0.00 $0.00 $0.00

34 0 $0.00 $0.00 $0.00 $0.00 $0.00

35 0 $0.00 $0.00 $0.00 $0.00 $0.00

36 0 $0.00 $0.00 $0.00 $0.00 $0.00

37 0 $0.00 $0.00 $0.00 $0.00 $0.00

38 0 $0.00 $0.00 $0.00 $0.00 $0.00

39 0 $0.00 $0.00 $0.00 $0.00 $0.00

40 0 $0.00 $0.00 $0.00 $0.00 $0.00

41 0 $0.00 $0.00 $0.00 $0.00 $0.00

42 0 $0.00 $0.00 $0.00 $0.00 $0.00

43 0 $0.00 $0.00 $0.00 $0.00 $0.00

44 0 $0.00 $0.00 $0.00 $0.00 $0.00

45 0 $0.00 $0.00 $0.00 $0.00 $0.00

46 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.21

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

Mark-up $6.01

T1 or OEM Total Manufacturing Cost: $0.21 $1.84 $3.35 $5.40 $0.02 $0.32 $0.24 $0.02 $0.60 $6.01 3

1

Notes: T1 or OEM Total Manufacturing Cost: $0.21 $1.84 $3.35 $5.40 $0.02 $0.32 $0.24 $0.02 $0.60 $6.01

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.03 $0.39 $0.36 $0.15 $0.93

Base Cost Impact to Vehicle: $0.21 $1.84 $3.35 $5.40 $0.05 $0.71 $0.61 $0.17 $1.54 $6.94 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $6.94

Notes: 

a) Items 1,2, & 3 m

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: 5 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Valve Actuation Piston Assy Part Number: 010705-N0200-04 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS Manufacturing C

Costs Broken O

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

76,596

10

North America

North America

FOB Ship Point

47

450,000

8

3,600,000

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

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

Packaging 

Cost per 

Piece

Total Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.001 $22,750 0.00% 18,000,000 60 5.00% $3,250 7 72000 6 459574

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: Option #3

Part Size: 2.5"L x 1"W x 1"H

Parts/Layer: 96

Number of Layers: 10

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: $0.001

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: 6 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

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

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

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

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

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

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

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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

Projected Operating Pattern Minimum Calculated Cycles Time 

Purchase Part - High Impact Item (Full Cost Mapping)

Valve Actuation Piston Assy: Valve Actuation 

Piston, Cap; Valve Actuation Piston, Cap 010705-N0200-04-01

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.14 $0.05 $0.19 $0.00 $0.01 $0.01 $0.00 $0.02 Assemble Valve Actuation Piston, Cap with Valve Actuation Piston, Cap and push into place 5 2 10 100 47 4700 766 4.70 85% 901 4.00 13 1 1 13 1.0 4.0

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

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin; Valve Actuation Piston, Spring 

Guide

010705-N0200-04-02

Valve Actuation Piston Assy: Valve Actuation 

Piston, Spring; Valve Actuation Piston, Housing; 

Valve Actuation Piston, Short Pin; Valve 

Actuation Piston, Yellow O-Ring; Valve 

Actuation Piston, Black O-Ring

010705-N0200-04-03

$0.13 $0.05 $0.18 $0.00 $0.01 $0.01 $0.00 $0.02 Assemble Valve Actuation Piston, Long Pin to Valve Actuation Piston, Spring Guide and press to depth 5 2 10 100 47 4700 766 4.70 85% 901 4.00 12 1 1 12 1.0 3.0

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

$0.12 $0.11 $0.24 $0.00 $0.01 $0.01 $0.00 $0.02 Assemble Valve Actuation Piston, Spring; Housing & Short Pin with Valve Yellow and Black O-Rings 5 2 10 100 47 4700 766 4.70 85% 901 4.00 27 1 1 27 1.0 7.0

$0.00 $0.00 $0.00 $0.00 $0.00 $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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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

Projected Operating Pattern 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

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-04

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-05

Valve Actuation Piston Assy: Valve Actuation 

Piston, Housing 010705-N0200-04-06

Valve Actuation Piston Assy: Valve Actuation 

Piston, Housing 010705-N0200-04-07

Valve Actuation Piston Assy: Valve Actuation 

Piston, Cap 010705-N0200-04-08

Valve Actuation Piston Assy: Valve Actuation 

Piston, Cap 010705-N0200-04-09

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-10

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-11

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

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

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

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

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

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

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

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

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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 $0.19 $0.23 $0.00 $0.02 $0.01 $0.00 $0.03 500 Ton Hot Forge w/ automated mat'l hdlg; operator cycles 5 2 10 100 47 4700 766 4.70 85% 901 4.00 6 1 1 6 1.0 2.0

$0.04 $0.14 $0.18 $0.00 $0.01 $0.01 $0.00 $0.03 Grind OD; operator load/unload & cycle 5 2 10 100 47 4700 766 4.70 85% 901 4.00 11 1 1 11 1.0 3.0

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

$0.05 $0.15 $0.20 $0.00 $0.01 $0.01 $0.00 $0.03 Grind OD; operator load/unload & cycle 5 2 10 100 47 4700 766 4.70 85% 901 4.00 12 1 1 12 1.0 3.0

$0.68 $0.72 $1.40 $0.00 $0.08 $0.06 $0.00 $0.14 Turn OD, End Faces & Undercuts; operator load/unload & cycle 5 2 10 100 47 4700 766 4.70 85% 901 4.00 126 1 1 126 1.0 32.0

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

$0.13 $0.14 $0.27 $0.00 $0.02 $0.01 $0.00 $0.03 Turn OD, End Faces & Undercuts; operator load/unload & cycle 5 2 10 100 47 4700 766 4.70 85% 901 4.00 24 1 1 24 1.0 6.0

$0.04 $0.32 $0.38 $0.00 $0.02 $0.02 $0.00 $0.05 500 Ton Hot Forge w/ automated mat'l hdlg; operator cycles 5 2 10 100 47 4700 766 4.70 85% 901 4.00 10 1 1 10 1.0 3.0

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

$0.07 $0.07 $0.14 $0.00 $0.01 $0.01 $0.00 $0.01 Turn OD, End Faces, cross drill lube hole; operator load/unload & cycle 5 2 10 100 47 4700 766 4.70 85% 901 4.00 13 1 1 13 1.0 4.0

$0.08 $0.45 $0.55 $0.00 $0.04 $0.03 $0.01 $0.08 500 Ton Hot Forge w/ automated mat'l hdlg; operator cycles 5 2 10 100 47 4700 766 4.70 85% 901 4.00 14 1 1 14 1.0 4.0

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-12

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

Valve Actuation Piston Assy: Valve Actuation 

Piston, Cap 010705-N0200-04-13

$0.05 $0.15 $0.20 $0.00 $0.01 $0.01 $0.00 $0.03 Grind OD; operator load/unload & cycle 5 2 10 100 47 4700 766 4.70 85% 901 4.00 12 1 1 12 1.0 3.0

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

$0.04 $0.14 $0.18 $0.00 $0.01 $0.01 $0.00 $0.02 Heat treat rocker pin; operator load/unload & cycle 5 2 10 100 47 4700 766 4.70 85% 901 4.00 10 1 1 10 1.0 3.0

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

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 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: 8 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-14

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-15

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-16

Valve Actuation Piston Assy: Valve Actuation 

Piston, Spring Guide 010705-N0200-04-17

Valve Actuation Piston Assy: Valve Actuation 

Piston, Spring Guide 010705-N0200-04-18

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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

Projected Operating Pattern Minimum Calculated Cycles Time 

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 766 4.70 85% 901 4.00 13 1 30 13 1.0 1.0

$0.04 $0.14 $0.18 $0.00 $0.01 $0.01 $0.00 $0.02 Heat treat Valve Actuation Piston, Long Pin; operator load/unload & cycle 5 2 10 100 47 4700 766 4.70 85% 901 4.00 10 1 1 10 1.0 3.0

$0.05 $0.13 $0.18 $0.00 $0.01 $0.01 $0.00 $0.02 Apply plating to Valve Actuation Piston, Long Pin; operator load/unload & cycle 5 2 10 100 47 4700 766 4.70 85% 901 4.00 9 1 2 9 1.0 1.0

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

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 766 4.70 85% 901 4.00 13 1 50 13 1.0 1.0

$0.00 $0.00 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 0-60 Ton Stamping Press w/ progressive die for Rocker Piston Cup; operator cycle controls 5 2 10 100 47 4700 766 4.70 85% 901 4.00 1 1 1 1 1.0 1.0

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

Valve Actuation Piston Assy: Valve Actuation 

Piston, Housing 010705-N0200-04-19

Valve Actuation Piston Assy: Valve Actuation 

Piston, Housing 010705-N0200-04-20

Valve Actuation Piston Assy: Valve Actuation 

Piston, Short Pin 010705-N0200-04-21

Valve Actuation Piston Assy: Valve Actuation 

Piston, Short Pin 010705-N0200-04-22

Valve Actuation Piston Assy: Valve Actuation 

Piston, Short Pin 010705-N0200-04-23

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

FM Valve Actuation Piston, Clip 010705-N0200-04-24

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

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 766 4.70 85% 901 4.00 13 1 50 13 1.0 1.0

$0.04 $0.14 $0.18 $0.00 $0.01 $0.01 $0.00 $0.02 Heat treat Valve Actuation Piston, Housing; operator load/unload & cycle 5 2 10 100 47 4700 766 4.70 85% 901 4.00 10 1 1 10 1.0 3.0

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

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 766 4.70 85% 901 4.00 13 1 30 13 1.0 1.0

$0.04 $0.14 $0.18 $0.00 $0.01 $0.01 $0.00 $0.02 Heat treat Valve Actuation Piston, Short Pin; operator load/unload & cycle 5 2 10 100 47 4700 766 4.70 85% 901 4.00 10 1 1 10 1.0 3.0

$0.05 $0.11 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02 Apply plating to Valve Actuation Piston, Short Pin; operator load/unload & cycle 5 2 10 100 47 4700 766 4.70 85% 901 4.00 8 1 2 8 1.0 1.0

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.02

FM Valve Actuation Piston, Spring 010705-N0200-04-25

FM Valve Actuation Piston, Yellow O-Ring 010705-N0200-04-26

FM Valve Actuation Piston, Black O-Ring 010705-N0200-04-27

$0.00

$0.01

$0.00

$0.07

$0.00

$0.06

$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: 9 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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

Projected Operating Pattern Minimum Calculated Cycles Time 

$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

$0.00

$0.00

$0.00

$0.00

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

Total

$1.84 $3.35 $5.40 $0.02 $0.32 $0.24 $0.02 $0.60

$6.01

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: 10 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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

Projected Operating Pattern 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: 11 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

Valve Actuation Piston Assy: Valve Actuation 

Piston, Cap; Valve Actuation Piston, Cap 010705-N0200-04-01

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

1108 3.25 4.00

#DIV/0! #DIV/0! -

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin; Valve Actuation Piston, Spring 

Guide

010705-N0200-04-02

Valve Actuation Piston Assy: Valve Actuation 

Piston, Spring; Valve Actuation Piston, Housing; 

Valve Actuation Piston, Short Pin; Valve 

Actuation Piston, Yellow O-Ring; Valve 

Actuation Piston, Black O-Ring

010705-N0200-04-03

900 4.00 3.00

#DIV/0! #DIV/0! -

933 3.86 3.00

#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: 12 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-04

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-05

Valve Actuation Piston Assy: Valve Actuation 

Piston, Housing 010705-N0200-04-06

Valve Actuation Piston Assy: Valve Actuation 

Piston, Housing 010705-N0200-04-07

Valve Actuation Piston Assy: Valve Actuation 

Piston, Cap 010705-N0200-04-08

Valve Actuation Piston Assy: Valve Actuation 

Piston, Cap 010705-N0200-04-09

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-10

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-11

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

1200 3.00 1.00

982 3.67 1.00

#DIV/0! #DIV/0! -

900 4.00 1.00

914 3.94 16.00

#DIV/0! #DIV/0! -

900 4.00 3.00

1080 3.33 1.00

#DIV/0! #DIV/0! -

1108 3.25 2.00

1029 3.50 2.00

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-12

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

Valve Actuation Piston Assy: Valve Actuation 

Piston, Cap 010705-N0200-04-13

900 4.00 1.00

#DIV/0! #DIV/0! -

1080 3.33 1.00

#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: 13 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-14

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-15

Valve Actuation Piston Assy: Valve Actuation 

Piston, Long Pin 010705-N0200-04-16

Valve Actuation Piston Assy: Valve Actuation 

Piston, Spring Guide 010705-N0200-04-17

Valve Actuation Piston Assy: Valve Actuation 

Piston, Spring Guide 010705-N0200-04-18

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

8308 0.43 0.25

1080 3.33 1.00

800 4.50 1.00

#DIV/0! #DIV/0! -

13846 0.26 0.25

3600 1.00 0.25

#DIV/0! #DIV/0! -

Valve Actuation Piston Assy: Valve Actuation 

Piston, Housing 010705-N0200-04-19

Valve Actuation Piston Assy: Valve Actuation 

Piston, Housing 010705-N0200-04-20

Valve Actuation Piston Assy: Valve Actuation 

Piston, Short Pin 010705-N0200-04-21

Valve Actuation Piston Assy: Valve Actuation 

Piston, Short Pin 010705-N0200-04-22

Valve Actuation Piston Assy: Valve Actuation 

Piston, Short Pin 010705-N0200-04-23

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

FM Valve Actuation Piston, Clip 010705-N0200-04-24

#DIV/0! #DIV/0! -

13846 0.26 0.25

1080 3.33 1.00

#DIV/0! #DIV/0! -

8308 0.43 0.25

1080 3.33 1.00

900 4.00 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! -

FM Valve Actuation Piston, Spring 010705-N0200-04-25

FM Valve Actuation Piston, Yellow O-Ring 010705-N0200-04-26

FM Valve Actuation Piston, Black O-Ring 010705-N0200-04-27

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 14 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 15 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Oil Control Solenoid Assy Part Number: 010705-N0200-05 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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

North America

North America

FOB Ship Point

47

450,000

4

1,800,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

38,298

10

Costs Broken Ou

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Co

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

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

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

Oil Control Solenoid: Solenoid Plunger Assy; 

Solenoid Shell; Electrical Assembly 010705-N0200-05-01 1

Assemble Solenoid Plunger 

Assy; Solenoid Shell - press & 

stake; Flip Sub & press 

electrical asm into place

T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 540 3 3 1 0.000 $0.00 $38.55 $15.00 $45.00 $0.00 $0.21 $0.08 $0.30 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.33 $0.33 $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 Oil Control Solenoid: FM Label, Solenoid 010705-N0200-05-02 1

Air / Elect Test on Solenoid. 

Print & Apply FM Label, 

Solenoid upon passing.

T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Elec. Assembly, LC, Base 450 3 3 1 0.000 $0.00 $38.55 $15.00 $45.00 $0.00 $0.26 $0.10 $0.36 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.39 $0.39 $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

Solenoid Plunger Assy: Solenoid Plunger 

Housing; Solenoid Plunger Stop 010705-N0200-05-03 1

Assemble Solenoid Plunger 

Housing with Solenoid Plunger 

Stop - press into place

T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 450 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.17 $0.07 $0.24 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.26 $0.26 $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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Oil Control Solenoid Assy Part Number: 010705-N0200-05 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

4

1,800,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

38,298

10

Costs Broken Ou

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Co

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

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

7

Oil Control Solenoid: Solenoid Plunger SubAssy; 

Solenoid Plunger Pin Assy; Solenoid Plunger 

Spring, Large; Solenoid Plunger Spring, Small

010705-N0200-05-04 1

Assemble Solenoid Plunger 

SubAssy; Solenoid Plunger Pin 

Assy; Spring, Large & Spring, 

Small - press into place

T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 576 4 4 1 0.000 $0.00 $38.55 $15.00 $60.00 $0.00 $0.27 $0.10 $0.37 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.41 $0.41 $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

Oil Control Solenoid: Solenoid Plunger Nose 

Piece 010705-N0200-05-05 1

Assemble Solenoid Plunger 

Nose Piece - press into place T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 600 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.06 $0.03 $0.09 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.10 $0.10 $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

31 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

32 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

33 Oil Control Solenoid Assy: Solenoid Plunger 

Housing 010705-N0200-05-06 1 CNC Turning T2/T3 CNC Turning, SSLC Not Applicable Lathe/Turning Operator CNC Turning, SS, BF, DA 456 3 10 1 0.200 $0.00 $38.97 $20.48 $204.80 $0.00 $0.26 $0.45 $0.71 0.30% 6.00% 4.00% 0.00% 10.30% $0.07 $0.78 $0.78 $0.00

34 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

35 Solenoid Plunger Assy: Solenoid Plunger Stop 010705-N0200-05-07 1 CNC Turning T2/T3 CNC Turning, SSLC Not Applicable Lathe/Turning Operator CNC Turning, SS, BF, DA 480 2 4 1 0.000 $0.00 $38.97 $20.48 $81.92 $0.00 $0.16 $0.17 $0.33 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.37 $0.37 $0.00

36 Solenoid Plunger Assy: Solenoid Plunger Stop 010705-N0200-05-08 1 Forging T2/T3 Forge, MSMC LC-Steel-1214, Bar Forging Operator Forge, SS 450 1 1 1 0.005 $1.00 $40.18 $115.72 $115.72 $0.01 $0.09 $0.26 $0.35 0.50% 6.50% 6.00% 1.00% 14.00% $0.05 $0.40 $0.40 $0.01

37 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

38 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

39 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

40 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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

Oil Control Solenoid Assy: Solenoid Plunger 

Housing 010705-N0200-05-09 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 4154 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.01 $0.01 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.01 $0.01 $0.00

7

Oil Control Solenoid Assy: Solenoid Plunger 

Housing 010705-N0200-05-10 1 Plating T2/T3 Plate/Finish Elect., SSLC Not Applicable Plating/Coating Operator Plate Elect., SMS, LMC 720 0.5 1 1 0.000 $0.00 $40.84 $100.18 $100.18 $0.00 $0.03 $0.14 $0.17 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $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

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Oil Control Solenoid Assy Part Number: 010705-N0200-05 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

4

1,800,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

38,298

10

Costs Broken Ou

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Co

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

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

5 Solenoid Plunger Assy: Solenoid Plunger Stop 010705-N0200-05-11 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 8308 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.00 $0.00 $0.00

6 Solenoid Plunger Assy: Solenoid Plunger Stop 010705-N0200-05-12 1 Heat Treat T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC 720 1 2 1 0.000 $0.00 $47.72 $50.00 $100.00 $0.00 $0.07 $0.14 $0.21 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.23 $0.23 $0.00

7 Solenoid Plunger Assy: Solenoid Plunger Stop 010705-N0200-05-13 1 Plating T2/T3 Plate/Finish Elect., SSLC Not Applicable Plating/Coating Operator Plate Elect., SMS, LMC 800 0.5 1 1 0.000 $0.00 $40.84 $100.18 $100.18 $0.00 $0.03 $0.13 $0.15 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.17 $0.17 $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

Oil Control Solenoid: Solenoid Plunger Nose 

Piece 010705-N0200-05-14 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 13846 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.00 $0.00 $0.00

10 Oil Control Solenoid: Solenoid Plunger Nose 

Piece 010705-N0200-05-15 1 Stamp Press T2/T3 Stamp/Form, LSHC LC-Steel-1214, Bar Cut/Punch/Forming Operator Stamp/Form, Terminals 3600 0.25 1 1 0.003 $0.62 $42.73 $15.50 $15.50 $0.00 $0.00 $0.00 $0.01 0.70% 7.00% 8.00% 2.00% 17.70% $0.00 $0.01 $0.01 $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

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 FM Label, Solenoid 010705-N0502-05-16 1 (qtys applied on CMAT) S $0.00 $0.05 $0.00 $0.05 $0.05

2 0 $0.00 $0.00 $0.00 $0.00 $0.00

3 FM Solenoid Plunger Spring, Large 010705-N0502-05-17 1 (qtys applied on CMAT) S $0.00 $0.01 $0.00 $0.01 $0.01

4 0 $0.00 $0.00 $0.00 $0.00 $0.00

5 FM Solenoid Plunger Spring, Small 010705-N0502-05-18 1 (qtys applied on CMAT) S $0.00 $0.01 $0.00 $0.01 $0.01

6 0 $0.00 $0.00 $0.00 $0.00 $0.00

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

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

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

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

Mark-up Calculations.

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

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

Mark-up Calculations.

"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: 4 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Oil Control Solenoid Assy Part Number: 010705-N0200-05 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

4

1,800,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

38,298

10

Costs Broken Ou

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Co

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

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

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

31 0 $0.00 $0.00 $0.00 $0.00 $0.00

32 0 $0.00 $0.00 $0.00 $0.00 $0.00

33 0 $0.00 $0.00 $0.00 $0.00 $0.00

34 0 $0.00 $0.00 $0.00 $0.00 $0.00

35 0 $0.00 $0.00 $0.00 $0.00 $0.00

36 0 $0.00 $0.00 $0.00 $0.00 $0.00

37 0 $0.00 $0.00 $0.00 $0.00 $0.00

38 0 $0.00 $0.00 $0.00 $0.00 $0.00

39 0 $0.00 $0.00 $0.00 $0.00 $0.00

40 0 $0.00 $0.00 $0.00 $0.00 $0.00

41 0 $0.00 $0.00 $0.00 $0.00 $0.00

42 0 $0.00 $0.00 $0.00 $0.00 $0.00

43 0 $0.00 $0.00 $0.00 $0.00 $0.00

44 0 $0.00 $0.00 $0.00 $0.00 $0.00

45 0 $0.00 $0.00 $0.00 $0.00 $0.00

46 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.08

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

Mark-up $3.71

T1 or OEM Total Manufacturing Cost: $0.08 $1.61 $1.67 $3.36 $0.01 $0.20 $0.14 $0.00 $0.35 $3.71

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.02 $0.24 $0.22 $0.09 $0.58

Base Cost Impact to Vehicle: $0.08 $1.61 $1.67 $3.36 $0.03 $0.44 $0.36 $0.10 $0.93 $4.29 $0 $0

Packaging Cost: $0.01

Net Cost Impact to Vehicle: $4.29

3

1

Notes: 

a) Items 1,2, & 3 mu

Net Cost Impact to Vehicle: $4.29

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

PACKAGING CALCULATIONS: 

Packaging Type: Option #3

Part Size: 2.5"L x 2"W x 1.25"H

Parts/Layer: 48

Number of Layers: 9

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

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Oil Control Solenoid Assy Part Number: 010705-N0200-05 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

4

1,800,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

38,298

10

Costs Broken Ou

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Co

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

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

Rack/Pallet Investment Amortization: $0.005 $42,250 0.00% 9,000,000 60 5.00% $3,250 13 18144 6 229787

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: $0.005

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: 6 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

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

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

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

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

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

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

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

Purchase Part - High Impact Item (Full Cost Mapping)

Oil Control Solenoid: Solenoid Plunger Assy; 

Solenoid Shell; Electrical Assembly 010705-N0200-05-01

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.21 $0.08 $0.30 $0.00 $0.02 $0.01 $0.00 $0.03 Assemble Solenoid Plunger Assy in Solenoid Shell press & ID/OD stake; operator load/unload & cycle press & stake tool press 5 2 10 100 47 4700 383 9.40 85% 451 7.99 20 1 1 20 1.0 3.0

Oil Control Solenoid: FM Label, Solenoid 010705-N0200-05-02

Solenoid Plunger Assy: Solenoid Plunger 

Housing; Solenoid Plunger Stop 010705-N0200-05-03

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

$0.26 $0.10 $0.36 $0.00 $0.02 $0.01 $0.00 $0.04 Air / Elect Test on Solenoid unit. Pressure vs electrical feedback. Print & Apply FM Label, Solenoid upon passing. 5 2 10 100 47 4700 383 9.40 85% 451 7.99 24 1 1 24 1.0 3.0

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

$0.17 $0.07 $0.24 $0.00 $0.01 $0.01 $0.00 $0.02 Assemble Solenoid Plunger Housing with Solenoid Plunger Stop - press into place 5 2 10 100 47 4700 383 9.40 85% 451 7.99 16 1 1 16 1.0 2.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Oil Control Solenoid: Solenoid Plunger SubAssy; 

Solenoid Plunger Pin Assy; Solenoid Plunger 

Spring, Large; Solenoid Plunger Spring, Small

010705-N0200-05-04

Oil Control Solenoid: Solenoid Plunger Nose 

Piece 010705-N0200-05-05

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.27 $0.10 $0.37 $0.00 $0.02 $0.01 $0.00 $0.04 Assemble Solenoid Plunger SubAssy; Solenoid Plunger Pin Assy; Spring, Large & Spring, Small - press 

into place w/ press assist tool 5 2 10 100 47 4700 383 9.40 85% 451 7.99 25 1 1 25 1.0 4.0

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

$0.06 $0.03 $0.09 $0.00 $0.01 $0.00 $0.00 $0.01 Assemble Solenoid Plunger Nose Piece - press into place with press assist tool 5 2 10 100 47 4700 383 9.40 85% 451 7.99 6 1 1 6 1.0 1.0

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

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

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

Oil Control Solenoid Assy: Solenoid Plunger 

Housing 010705-N0200-05-06

Solenoid Plunger Assy: Solenoid Plunger Stop 010705-N0200-05-07

Solenoid Plunger Assy: Solenoid Plunger Stop 010705-N0200-05-08

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.26 $0.45 $0.71 $0.00 $0.04 $0.03 $0.00 $0.07 Turn OD, ID, End Faces, Undercut & Drill Holes; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 79 1 1 79 1.0 10.0

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

$0.16 $0.17 $0.33 $0.00 $0.02 $0.01 $0.00 $0.03 Turn OD, Drill, Chamfer; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 30 1 1 30 1.0 4.0

$0.09 $0.26 $0.35 $0.00 $0.02 $0.02 $0.00 $0.05 500 Ton Hot Forge w/ automated mat'l hdlg; operator cycles 5 2 10 100 47 4700 383 9.40 85% 451 7.99 8 1 1 8 1.0 1.0

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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)

Oil Control Solenoid Assy: Solenoid Plunger 

Housing 010705-N0200-05-09

Oil Control Solenoid Assy: Solenoid Plunger 

Housing 010705-N0200-05-10

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

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

$0.00 $0.01 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 383 9.40 85% 451 7.99 13 1 15 13 1.0 1.0

$0.03 $0.14 $0.17 $0.00 $0.01 $0.01 $0.00 $0.02 Apply plating to Solenoid Plunger Housing; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 10 1 2 10 1.0 1.0

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

$0.00 $0.00 $0.00 $0.00 $0.00 $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: 8 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Solenoid Plunger Assy: Solenoid Plunger Stop 010705-N0200-05-11

Solenoid Plunger Assy: Solenoid Plunger Stop 010705-N0200-05-12

Solenoid Plunger Assy: Solenoid Plunger Stop 010705-N0200-05-13

Oil Control Solenoid: Solenoid Plunger Nose 

Piece 010705-N0200-05-14

Oil Control Solenoid: Solenoid Plunger Nose 

Piece 010705-N0200-05-15

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 383 9.40 85% 451 7.99 13 1 30 13 1.0 1.0

$0.07 $0.14 $0.21 $0.00 $0.01 $0.01 $0.00 $0.02 Heat treat Solenoid Plunger Stop; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 10 1 1 10 1.0 2.0

$0.03 $0.13 $0.15 $0.00 $0.01 $0.01 $0.00 $0.02 Apply plating to Solenoid Plunger Stop; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 9 1 2 9 1.0 1.0

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

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 383 9.40 85% 451 7.99 13 1 50 13 1.0 1.0

$0.00 $0.00 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 0-60 Ton Stamping Press w/ progressive die for Solenoid Plunger Nose Piece; operator cycle controls 5 2 10 100 47 4700 383 9.40 85% 451 7.99 1 1 1 1 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $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 - Commodity ( Value taken from Purchase Part Database)

FM Label, Solenoid 010705-N0502-05-16

FM Solenoid Plunger Spring, Large 010705-N0502-05-17

FM Solenoid Plunger Spring, Small 010705-N0502-05-18

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.05

$0.00

$0.01

$0.00

$0.01

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$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: 9 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$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

$1.61 $1.67 $3.36 $0.01 $0.20 $0.14 $0.00 $0.35

$3.71

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: 10 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

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

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

File: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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

Oil Control Solenoid: Solenoid Plunger Assy; 

Solenoid Shell; Electrical Assembly 010705-N0200-05-01

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

540 6.67 3.00

Oil Control Solenoid: FM Label, Solenoid 010705-N0200-05-02

Solenoid Plunger Assy: Solenoid Plunger 

Housing; Solenoid Plunger Stop 010705-N0200-05-03

#DIV/0! #DIV/0! -

450 8.00 3.00

#DIV/0! #DIV/0! -

450 8.00 2.00

#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: 12 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Oil Control Solenoid: Solenoid Plunger SubAssy; 

Solenoid Plunger Pin Assy; Solenoid Plunger 

Spring, Large; Solenoid Plunger Spring, Small

010705-N0200-05-04

Oil Control Solenoid: Solenoid Plunger Nose 

Piece 010705-N0200-05-05

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

576 6.25 4.00

#DIV/0! #DIV/0! -

600 6.00 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Oil Control Solenoid Assy: Solenoid Plunger 

Housing 010705-N0200-05-06

Solenoid Plunger Assy: Solenoid Plunger Stop 010705-N0200-05-07

Solenoid Plunger Assy: Solenoid Plunger Stop 010705-N0200-05-08

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

456 7.90 3.00

#DIV/0! #DIV/0! -

480 7.50 2.00

450 8.00 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

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

Oil Control Solenoid Assy: Solenoid Plunger 

Housing 010705-N0200-05-09

Oil Control Solenoid Assy: Solenoid Plunger 

Housing 010705-N0200-05-10

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

4154 0.87 0.25

720 5.00 0.50

#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: 13 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Solenoid Plunger Assy: Solenoid Plunger Stop 010705-N0200-05-11

Solenoid Plunger Assy: Solenoid Plunger Stop 010705-N0200-05-12

Solenoid Plunger Assy: Solenoid Plunger Stop 010705-N0200-05-13

Oil Control Solenoid: Solenoid Plunger Nose 

Piece 010705-N0200-05-14

Oil Control Solenoid: Solenoid Plunger Nose 

Piece 010705-N0200-05-15

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

8308 0.43 0.25

720 5.00 1.00

800 4.50 0.50

#DIV/0! #DIV/0! -

13846 0.26 0.25

3600 1.00 0.25

#DIV/0! #DIV/0! -

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

FM Label, Solenoid 010705-N0502-05-16

FM Solenoid Plunger Spring, Large 010705-N0502-05-17

FM Solenoid Plunger Spring, Small 010705-N0502-05-18

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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: 14 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810e7549.xls

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

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 15 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Plunger SubAssy Part Number: 010705-N0200-06 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

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

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

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

38,298

10

North America

North America

FOB Ship Point

47

450,000

4

1,800,000

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

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

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

Solenoid Plunger SubAssy: Solenoid Plunger 

Frame; Solenoid Plunger Frame Piston Stop; 

Solenoid Plunger Piston Assy; Solenoid Plunger 

Piston Spring; Solenoid Plunger Piston Body 

Assy

010705-N0200-06-01 1

Assemble Solenoid Plunger 

Frame; Piston Stop; Piston 

Assy; Piston Spring with Piston 

Body Assy - press & crimp 

together

T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 514 3 3 1 0.000 $0.00 $38.55 $15.00 $45.00 $0.00 $0.22 $0.09 $0.31 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.34 $0.34 $0.00

2 Solenoid Plunger SubAssy: 010705-N0200-06-02 1

Laser Weld Piston Body Assy in 

place T2/T3 Mech. Assembly, MSMC Not Applicable Welding/Soldering Operator Mech Assembly, MC, Base 720 2 2 1 0.000 $0.00 $41.55 $30.00 $60.00 $0.00 $0.12 $0.08 $0.20 0.50% 6.50% 6.00% 1.00% 14.00% $0.03 $0.23 $0.23 $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

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body; Solenoid Plunger Piston Body 

Shaft

010705-N0200-06-03 1

Assemble Solenoid Plunger 

Piston Body to Solenoid 

Plunger Piston Body Shaft & 

press together

T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 400 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.10 $0.04 $0.13 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.15 $0.15 $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

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Plunger SubAssy Part Number: 010705-N0200-06 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

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

38,298

10

North America

North America

FOB Ship Point

47

450,000

4

1,800,000

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

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

6

Solenoid Plunger Piston Body Assy: Solenoid 

Plunger Piston Body Assy, Body; Solenoid 

Plunger Piston Body Assy, Insert

010705-N0200-06-04 1

Assemble Solenoid Plunger 

Piston Body Assy, Body & 

Solenoid Plunger Piston Body 

Assy, Insert

T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 400 1 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.10 $0.04 $0.13 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.15 $0.15 $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 Solenoid Plunger Piston Body Assy: Solenoid 

Plunger Piston Body Assy, Insert 010705-N0200-06-05 1 CNC Turning T2/T3 CNC Turning, SSLC LC-Steel-1214, Bar Lathe/Turning Operator CNC Turning, SS, BF, DA 450 3 5 1 0.005 $0.62 $38.97 $20.48 $102.40 $0.00 $0.26 $0.23 $0.49 0.30% 6.00% 4.00% 0.00% 10.30% $0.05 $0.54 $0.54 $0.00

31 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

32 Solenoid Plunger Piston Body Assy: Solenoid 

Plunger Piston Body Assy, Body 010705-N0200-06-06 1 Grinding T2/T3 CNC Milling, MSMC Not Applicable Grinding/Polishing Operator Grinding, SS 720 1 2 1 0.000 $0.00 $42.14 $45.00 $90.00 $0.00 $0.06 $0.13 $0.18 0.50% 6.50% 6.00% 1.00% 14.00% $0.03 $0.21 $0.21 $0.00

33 Solenoid Plunger Piston Body Assy: Solenoid 

Plunger Piston Body Assy, Body 010705-N0200-06-07 1 CNC Turning T2/T3 CNC Turning, SSLC LC-Steel-1214, Bar Lathe/Turning Operator CNC Turning, SS, BF, DA 488 4 8 1 0.060 $0.62 $38.97 $20.48 $163.84 $0.04 $0.32 $0.34 $0.69 0.30% 6.00% 4.00% 0.00% 10.30% $0.07 $0.76 $0.76 $0.04

34 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

35 Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body 010705-N0200-06-08 1 CNC Turning T2/T3 CNC Turning, SSLC Not Applicable Lathe/Turning Operator CNC Turning, SS, BF, DA 800 1 2 1 0.000 $0.00 $38.97 $20.48 $40.96 $0.00 $0.05 $0.05 $0.10 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.11 $0.11 $0.00

36 Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body 010705-N0200-06-09 1 Forging T2/T3 Forge, MSMC LC-Steel-1214, Bar Forging Operator Forge, SS 450 1 1 1 0.020 $1.00 $40.18 $115.72 $115.72 $0.02 $0.09 $0.26 $0.37 0.50% 6.50% 6.00% 1.00% 14.00% $0.05 $0.42 $0.42 $0.02

37 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

38 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

39 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

40 Solenoid Plunger SubAssy: Solenoid Plunger 

Frame Piston Stop 010705-N0200-06-10 1 Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 5143 0.25 1 1 0.001 $1.74 $41.48 $16.39 $16.39 $0.00 $0.00 $0.00 $0.01 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.01 $0.01 $0.00

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

1

Solenoid Plunger Piston Body Assy: Solenoid 

Plunger Piston Body Assy, Insert 010705-N0200-06-11 1 Heat Treat T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC 720 1 2 1 0.000 $0.00 $47.72 $50.00 $100.00 $0.00 $0.07 $0.14 $0.21 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.23 $0.23 $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

Solenoid Plunger Piston Body Assy: Solenoid 

Plunger Piston Body Assy, Body 010705-N0200-06-12 1 Heat Treat T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC 720 1 2 1 0.000 $0.00 $47.72 $50.00 $100.00 $0.00 $0.07 $0.14 $0.21 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.23 $0.23 $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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Plunger SubAssy Part Number: 010705-N0200-06 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

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

38,298

10

North America

North America

FOB Ship Point

47

450,000

4

1,800,000

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

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

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

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body 010705-N0200-06-13 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 8308 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.00 $0.00 $0.00

6

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body 010705-N0200-06-14 1 Heat Treat T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC 720 1 2 1 0.000 $0.00 $47.72 $50.00 $100.00 $0.00 $0.07 $0.14 $0.21 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.23 $0.23 $0.00

7

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body 010705-N0200-06-15 1 Plating T2/T3 Plate/Finish Elect., SSLC Not Applicable Plating/Coating Operator Plate Elect., SMS, LMC 800 0.5 1 1 0.000 $0.00 $40.84 $100.18 $100.18 $0.00 $0.03 $0.13 $0.15 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.17 $0.17 $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

Solenoid Plunger SubAssy: Solenoid Plunger 

Frame 010705-N0200-06-16 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 13846 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.00 $0.00 $0.00

10 Solenoid Plunger SubAssy: Solenoid Plunger 

Frame 010705-N0200-06-17 1 Stamp Press T2/T3 Stamp/Form, LSHC S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals 3600 0.25 1 1 0.005 $1.64 $42.73 $15.50 $15.50 $0.01 $0.00 $0.00 $0.02 0.70% 7.00% 8.00% 2.00% 17.70% $0.00 $0.02 $0.02 $0.01

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 Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body Shaft 010705-N0200-06-18 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 13846 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.00 $0.00 $0.00

13 Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body Shaft 010705-N0200-06-19 1 Stamp Press T2/T3 Stamp/Form, LSHC S-Steel-304, Coil Cut/Punch/Forming Operator Stamp/Form, XSS 554 1 2 1 0.005 $1.64 $42.73 $24.60 $49.20 $0.01 $0.08 $0.09 $0.17 0.70% 7.00% 8.00% 2.00% 17.70% $0.03 $0.21 $0.21 $0.01

14 Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body Shaft 010705-N0200-06-20 1 Heat Treat T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC 720 1 2 1 0.000 $0.00 $47.72 $50.00 $100.00 $0.00 $0.07 $0.14 $0.21 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.23 $0.23 $0.00

15 Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body Shaft 010705-N0200-06-21 1 Deburr T2/T3 Mech. Assembly, SSLC Not Applicable Grinding/Polishing Operator Grinding, SS 12857 0.25 1 1 0.000 $0.00 $42.14 $45.00 $45.00 $0.00 $0.00 $0.00 $0.00 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.00 $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

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 FM Solenoid Plunger Piston Spring 010705-N0200-06-22 1 (qtys applied on CMAT) S $0.00 $0.01 $0.00 $0.01 $0.01 "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub2 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

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

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

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

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

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

Mark-up Calculations.

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

Supplier for Subassembly.

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Plunger SubAssy Part Number: 010705-N0200-06 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

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

38,298

10

North America

North America

FOB Ship Point

47

450,000

4

1,800,000

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

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

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

31 0 $0.00 $0.00 $0.00 $0.00 $0.00

32 0 $0.00 $0.00 $0.00 $0.00 $0.00

33 0 $0.00 $0.00 $0.00 $0.00 $0.00

34 0 $0.00 $0.00 $0.00 $0.00 $0.00

35 0 $0.00 $0.00 $0.00 $0.00 $0.00

36 0 $0.00 $0.00 $0.00 $0.00 $0.00

37 0 $0.00 $0.00 $0.00 $0.00 $0.00

38 0 $0.00 $0.00 $0.00 $0.00 $0.00

39 0 $0.00 $0.00 $0.00 $0.00 $0.00

40 0 $0.00 $0.00 $0.00 $0.00 $0.00

41 0 $0.00 $0.00 $0.00 $0.00 $0.00

42 0 $0.00 $0.00 $0.00 $0.00 $0.00

43 0 $0.00 $0.00 $0.00 $0.00 $0.00

44 0 $0.00 $0.00 $0.00 $0.00 $0.00

45 0 $0.00 $0.00 $0.00 $0.00 $0.00

46 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.09

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

Mark-up $4.23

T1 or OEM Total Manufacturing Cost: $0.09 $1.68 $2.03 $3.80 $0.01 $0.23 $0.17 $0.01 $0.43 $4.23 3

1

Notes: T1 or OEM Total Manufacturing Cost: $0.09 $1.68 $2.03 $3.80 $0.01 $0.23 $0.17 $0.01 $0.43 $4.23

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.02 $0.28 $0.25 $0.11 $0.66

Base Cost Impact to Vehicle: $0.09 $1.68 $2.03 $3.80 $0.03 $0.51 $0.43 $0.12 $1.09 $4.89 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $4.89

Notes: 

a) Items 1,2, & 3 mus

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: 5 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

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

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Plunger SubAssy Part Number: 010705-N0200-06 Weekly Component Volume: Packaging Specification: Returnable Dunnage

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

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

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

38,298

10

North America

North America

FOB Ship Point

47

450,000

4

1,800,000

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

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

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 9,000,000 60 5.00% $0 230 1000 6 229787

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: 6 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

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

GENERAL COMPONENT INFORMATION

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

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

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

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

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

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

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

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

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

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

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

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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

Projected Operating Pattern Minimum Calculated Cycles Time 

Purchase Part - High Impact Item (Full Cost Mapping)

Solenoid Plunger SubAssy: Solenoid Plunger 

Frame; Solenoid Plunger Frame Piston Stop; 

Solenoid Plunger Piston Assy; Solenoid Plunger 

Piston Spring; Solenoid Plunger Piston Body 

Assy

010705-N0200-06-01

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

$0.22 $0.09 $0.31 $0.00 $0.02 $0.01 $0.00 $0.03 Assemble Solenoid Plunger Frame; Piston Stop; Piston Assy; Piston Spring with Piston Body Assy - press & crimp together w/ 

tool assist 5 2 10 100 47 4700 383 9.40 85% 451 7.99 21 1 1 21 1.0 3.0

Solenoid Plunger SubAssy: 010705-N0200-06-02

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body; Solenoid Plunger Piston Body 

Shaft

010705-N0200-06-03

$0.12 $0.08 $0.20 $0.00 $0.01 $0.01 $0.00 $0.03 Laser Weld Piston Body Assy in place; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 10 1 1 10 1.0 2.0

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

$0.10 $0.04 $0.13 $0.00 $0.01 $0.01 $0.00 $0.01 Assemble Solenoid Plunger Piston Body to Solenoid Plunger Piston Body Shaft & press together 5 2 10 100 47 4700 383 9.40 85% 451 7.99 9 1 1 9 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

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

Solenoid Plunger Piston Body Assy: Solenoid 

Plunger Piston Body Assy, Body; Solenoid 

Plunger Piston Body Assy, Insert

010705-N0200-06-04

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

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

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

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

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

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

Projected Operating Pattern Minimum Calculated Cycles Time 

$0.10 $0.04 $0.13 $0.00 $0.01 $0.01 $0.00 $0.01 Assemble Solenoid Plunger Piston Body Assy, Body & Solenoid Plunger Piston Body Assy, Insert 5 2 10 100 47 4700 383 9.40 85% 451 7.99 9 1 1 9 1.0 1.0

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

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

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Solenoid Plunger Piston Body Assy: Solenoid 

Plunger Piston Body Assy, Insert 010705-N0200-06-05

Solenoid Plunger Piston Body Assy: Solenoid 

Plunger Piston Body Assy, Body 010705-N0200-06-06

Solenoid Plunger Piston Body Assy: Solenoid 

Plunger Piston Body Assy, Body 010705-N0200-06-07

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body 010705-N0200-06-08

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body 010705-N0200-06-09

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.26 $0.23 $0.49 $0.00 $0.03 $0.02 $0.00 $0.05 Turn OD, Drill & Chamfer ID; operator cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 40 1 1 40 1.0 5.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.06 $0.13 $0.18 $0.00 $0.01 $0.01 $0.00 $0.03 Grind ODs; operator load & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 10 1 1 10 1.0 2.0

$0.32 $0.34 $0.69 $0.00 $0.04 $0.03 $0.00 $0.07 Turn OD, Drill & Chamfer ID, Undercuts, Tap ID; operator cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 59 1 1 59 1.0 8.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.05 $0.05 $0.10 $0.00 $0.01 $0.00 $0.00 $0.01 Drill ID & step ID; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 9 1 1 9 1.0 2.0

$0.09 $0.26 $0.37 $0.00 $0.02 $0.02 $0.00 $0.05 500 Ton Hot Forge w/ automated mat'l hdlg; operator cycles 5 2 10 100 47 4700 383 9.40 85% 451 7.99 8 1 1 8 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Solenoid Plunger SubAssy: Solenoid Plunger 

Frame Piston Stop 010705-N0200-06-10

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Solenoid Plunger Piston Body Assy: Solenoid 

Plunger Piston Body Assy, Insert 010705-N0200-06-11

Solenoid Plunger Piston Body Assy: Solenoid 

Plunger Piston Body Assy, Body 010705-N0200-06-12

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Mold Solenoid Plunger Frame Piston Stop; operator cycle operation 5 2 10 100 47 4700 383 9.40 85% 451 7.99 7 1 10 7 1.0 1.0

$0.07 $0.14 $0.21 $0.00 $0.01 $0.01 $0.00 $0.02 Heat treat Solenoid Plunger Piston Body Assy, Insert; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 10 1 1 10 1.0 2.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.07 $0.14 $0.21 $0.00 $0.01 $0.01 $0.00 $0.02 Heat treat Solenoid Plunger Piston Body Assy, Body; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 10 1 1 10 1.0 2.0

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 8 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body 010705-N0200-06-13

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body 010705-N0200-06-14

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body 010705-N0200-06-15

Solenoid Plunger SubAssy: Solenoid Plunger 

Frame 010705-N0200-06-16

Solenoid Plunger SubAssy: Solenoid Plunger 

Frame 010705-N0200-06-17

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern 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 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 383 9.40 85% 451 7.99 13 1 30 13 1.0 1.0

$0.07 $0.14 $0.21 $0.00 $0.01 $0.01 $0.00 $0.02 Heat treat Solenoid Plunger Piston Body; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 10 1 1 10 1.0 2.0

$0.03 $0.13 $0.15 $0.00 $0.01 $0.01 $0.00 $0.02 Apply plating to Solenoid Plunger Piston Body; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 9 1 2 9 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 383 9.40 85% 451 7.99 13 1 50 13 1.0 1.0

$0.00 $0.00 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 0-60 Ton Stamping Press w/ progressive die for Solenoid Plunger Frame; operator cycle controls 5 2 10 100 47 4700 383 9.40 85% 451 7.99 1 1 1 1 1.0 1.0

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body Shaft 010705-N0200-06-18

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body Shaft 010705-N0200-06-19

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body Shaft 010705-N0200-06-20

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body Shaft 010705-N0200-06-21

Purchase Part - Commodity ( Value taken from Purchase Part Database)

FM Solenoid Plunger Piston Spring 010705-N0200-06-22

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 383 9.40 85% 451 7.99 13 1 50 13 1.0 1.0

$0.08 $0.09 $0.17 $0.00 $0.01 $0.01 $0.00 $0.03 60-200 Ton Stamping Press w/ progressive die for Solenoid Plunger Piston Body Shaft; operator cycle 

controls 5 2 10 100 47 4700 383 9.40 85% 451 7.99 13 1 1 13 1.0 2.0

$0.07 $0.14 $0.21 $0.00 $0.01 $0.01 $0.00 $0.02 Heat treat Solenoid Plunger Piston Body Shaft; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 10 1 1 10 1.0 2.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 Heat treat Solenoid Plunger Piston Body Shaft; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 14 1 50 14 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.01

$0.00

$0.00

$0.00

$0.00

$0.00

$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: 9 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern Minimum Calculated Cycles Time 

$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

$0.00

$0.00

$0.00

$0.00

Labor Burden TMC Scrape SG&A Profit ED&T Mark-up 

Total

$1.68 $2.03 $3.80 $0.01 $0.23 $0.17 $0.01 $0.43

$4.23

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: 10 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern 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: 11 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

Solenoid Plunger SubAssy: Solenoid Plunger 

Frame; Solenoid Plunger Frame Piston Stop; 

Solenoid Plunger Piston Assy; Solenoid Plunger 

Piston Spring; Solenoid Plunger Piston Body 

Assy

010705-N0200-06-01

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

514 7.00 3.00

Solenoid Plunger SubAssy: 010705-N0200-06-02

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body; Solenoid Plunger Piston Body 

Shaft

010705-N0200-06-03

720 5.00 2.00

#DIV/0! #DIV/0! -

400 9.00 1.00

#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: 12 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Solenoid Plunger Piston Body Assy: Solenoid 

Plunger Piston Body Assy, Body; Solenoid 

Plunger Piston Body Assy, Insert

010705-N0200-06-04

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

400 9.00 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! -

Solenoid Plunger Piston Body Assy: Solenoid 

Plunger Piston Body Assy, Insert 010705-N0200-06-05

Solenoid Plunger Piston Body Assy: Solenoid 

Plunger Piston Body Assy, Body 010705-N0200-06-06

Solenoid Plunger Piston Body Assy: Solenoid 

Plunger Piston Body Assy, Body 010705-N0200-06-07

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body 010705-N0200-06-08

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body 010705-N0200-06-09

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

450 8.00 3.00

#DIV/0! #DIV/0! -

720 5.00 1.00

488 7.38 4.00

#DIV/0! #DIV/0! -

800 4.50 1.00

450 8.00 1.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Solenoid Plunger SubAssy: Solenoid Plunger 

Frame Piston Stop 010705-N0200-06-10

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Solenoid Plunger Piston Body Assy: Solenoid 

Plunger Piston Body Assy, Insert 010705-N0200-06-11

Solenoid Plunger Piston Body Assy: Solenoid 

Plunger Piston Body Assy, Body 010705-N0200-06-12

#DIV/0! #DIV/0! -

5143 0.70 0.25

720 5.00 1.00

#DIV/0! #DIV/0! -

720 5.00 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: 13 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body 010705-N0200-06-13

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body 010705-N0200-06-14

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body 010705-N0200-06-15

Solenoid Plunger SubAssy: Solenoid Plunger 

Frame 010705-N0200-06-16

Solenoid Plunger SubAssy: Solenoid Plunger 

Frame 010705-N0200-06-17

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

8308 0.43 0.25

720 5.00 1.00

800 4.50 0.50

#DIV/0! #DIV/0! -

13846 0.26 0.25

3600 1.00 0.25

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body Shaft 010705-N0200-06-18

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body Shaft 010705-N0200-06-19

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body Shaft 010705-N0200-06-20

Solenoid Plunger Piston Assy: Solenoid Plunger 

Piston Body Shaft 010705-N0200-06-21

Purchase Part - Commodity ( Value taken from Purchase Part Database)

FM Solenoid Plunger Piston Spring 010705-N0200-06-22

#DIV/0! #DIV/0! -

13846 0.26 0.25

554 6.50 1.00

720 5.00 1.00

12857 0.28 0.25

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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: 14 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 15 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Plunger Pin Assy Part Number: 010705-N0200-07 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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

North America

North America

FOB Ship Point

47

450,000

4

1,800,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

38,298

10

Costs Broken Out 

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cos

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin; Solenoid Plunger Pin Spacer; Solenoid 

Plunger Pin Seal

010705-N0200-07-01 1

Assemble Solenoid Plunger Pin 

to Solenoid Plunger Pin Spacer 

& Solenoid Plunger Pin Seal

T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 480 2 2 1 0.000 $0.00 $38.55 $15.00 $30.00 $0.00 $0.16 $0.06 $0.22 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.25 $0.25 $0.00

2 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

3 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

4 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

5 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

6 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

7 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

8 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

9 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

10 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

11 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

12 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

13 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 2 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Plunger Pin Assy Part Number: 010705-N0200-07 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

4

1,800,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

38,298

10

Costs Broken Out 

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cos

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

14 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

15 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

16 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

17 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

18 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

19 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

20 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

21 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

22 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

23 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

24 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

25 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

26 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

27 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

28 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

29 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

30 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

31 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

32 Solenoid Plunger Pin Assy: Solenoid Shell 010705-N0200-07-02 1 CNC Turning T2/T3 CNC Turning, SSLC Not Applicable Lathe/Turning Operator CNC Turning, SS, BF, DA 450 3 5 1 0.150 $0.00 $38.97 $20.48 $102.40 $0.00 $0.26 $0.23 $0.49 0.30% 6.00% 4.00% 0.00% 10.30% $0.05 $0.54 $0.54 $0.00

33 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

34 Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin 010705-N0200-07-03 1 Grinding T2/T3 CNC Milling, MSMC Not Applicable Grinding/Polishing Operator Grinding, SS 720 1 2 1 0.000 $0.00 $42.14 $45.00 $90.00 $0.00 $0.06 $0.13 $0.18 0.50% 6.50% 6.00% 1.00% 14.00% $0.03 $0.21 $0.21 $0.00

35 Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin 010705-N0200-07-04 1 CNC Turning T2/T3 CNC Turning, SSLC Not Applicable Lathe/Turning Operator CNC Turning, SS, BF, DA 514 3 6 1 0.000 $0.00 $38.97 $20.48 $122.88 $0.00 $0.23 $0.24 $0.47 0.30% 6.00% 4.00% 0.00% 10.30% $0.05 $0.51 $0.51 $0.00

36 Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin 010705-N0200-07-05 1 Forging T2/T3 Forge, MSMC LC-Steel-1214, Bar Forging Operator Forge, SS 450 1 1 1 0.010 $1.00 $40.18 $115.72 $115.72 $0.01 $0.09 $0.26 $0.36 0.50% 6.50% 6.00% 1.00% 14.00% $0.05 $0.41 $0.41 $0.01

37 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

38 Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin Spacer 010705-N0200-07-06 1 CNC Turning T2/T3 CNC Turning, SSLC Not Applicable Lathe/Turning Operator CNC Turning, SS, BF, DA 514 3 5 1 0.005 $0.00 $38.97 $20.48 $102.40 $0.00 $0.23 $0.20 $0.43 0.30% 6.00% 4.00% 0.00% 10.30% $0.04 $0.47 $0.47 $0.00

39 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

40 Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin Seal 010705-N0200-07-07 1 Mold T2/T3 Inject. Mold, SSLC Nylon6, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 7200 0.25 1 1 0.000 $1.65 $41.48 $16.39 $16.39 $0.00 $0.00 $0.00 $0.00 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.00 $0.00 $0.00

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin Spacer 010705-N0200-07-08 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 8308 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.00 $0.00 $0.00

2

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin Spacer 010705-N0200-07-09 1 Heat Treat T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC 655 1 2 1 0.000 $0.00 $47.72 $50.00 $100.00 $0.00 $0.07 $0.15 $0.23 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.25 $0.25 $0.00

3

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin Spacer 010705-N0200-07-10 1 Plating T2/T3 Plate/Finish Elect., SSLC Not Applicable Plating/Coating Operator Plate Elect., SMS, LMC 900 0.5 1 1 0.000 $0.00 $40.84 $100.18 $100.18 $0.00 $0.02 $0.11 $0.13 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.15 $0.15 $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

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin 010705-N0200-07-11 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 8308 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.00 $0.00 $0.00

6

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin 010705-N0200-07-12 1 Heat Treat T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator Heat Treat, SMS, LMC 720 1 2 1 0.000 $0.00 $47.72 $50.00 $100.00 $0.00 $0.07 $0.14 $0.21 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.23 $0.23 $0.00

7

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin 010705-N0200-07-13 1 Plating T2/T3 Plate/Finish Elect., SSLC Not Applicable Plating/Coating Operator Plate Elect., SMS, LMC 900 0.5 1 1 0.000 $0.00 $40.84 $100.18 $100.18 $0.00 $0.02 $0.11 $0.13 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.15 $0.15 $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 Solenoid Plunger Pin Assy: Solenoid Shell 010705-N0200-07-14 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 5538 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.01 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.01 $0.01 $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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Plunger Pin Assy Part Number: 010705-N0200-07 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

4

1,800,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

38,298

10

Costs Broken Out 

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cos

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

10 Solenoid Plunger Pin Assy: Solenoid Shell 010705-N0200-07-15 1 Plating T2/T3 Plate/Finish Elect., SSLC Not Applicable Plating/Coating Operator Plate Elect., SMS, LMC 720 1 2 1 0.000 $0.00 $40.84 $100.18 $200.36 $0.00 $0.06 $0.28 $0.33 0.30% 6.00% 4.00% 0.00% 10.30% $0.03 $0.37 $0.37 $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

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

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

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

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

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Plunger Pin Assy Part Number: 010705-N0200-07 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

4

1,800,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

38,298

10

Costs Broken Out 

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cos

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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

31 0 $0.00 $0.00 $0.00 $0.00 $0.00

32 0 $0.00 $0.00 $0.00 $0.00 $0.00

33 0 $0.00 $0.00 $0.00 $0.00 $0.00

34 0 $0.00 $0.00 $0.00 $0.00 $0.00

35 0 $0.00 $0.00 $0.00 $0.00 $0.00

36 0 $0.00 $0.00 $0.00 $0.00 $0.00

37 0 $0.00 $0.00 $0.00 $0.00 $0.00

38 0 $0.00 $0.00 $0.00 $0.00 $0.00

39 0 $0.00 $0.00 $0.00 $0.00 $0.00

40 0 $0.00 $0.00 $0.00 $0.00 $0.00

41 0 $0.00 $0.00 $0.00 $0.00 $0.00

42 0 $0.00 $0.00 $0.00 $0.00 $0.00

43 0 $0.00 $0.00 $0.00 $0.00 $0.00

44 0 $0.00 $0.00 $0.00 $0.00 $0.00

45 0 $0.00 $0.00 $0.00 $0.00 $0.00

46 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.01

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $3.54

T1 or OEM Total Manufacturing Cost: $0.01 $1.27 $1.91 $3.19 $0.01 $0.19 $0.14 $0.01 $0.35 $3.54

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.02 $0.23 $0.21 $0.09 $0.55

Base Cost Impact to Vehicle: $0.01 $1.27 $1.91 $3.19 $0.03 $0.42 $0.35 $0.09 $0.90 $4.09 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $4.09

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

PACKAGING CALCULATIONS: 

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers:

3

1

Notes: 

a) Items 1,2, & 3 mus

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

Piece (%)

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 9,000,000 60 5.00% $0 230 1000 6 229787

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

Number of Layers: 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.)

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Plunger Pin Assy Part Number: 010705-N0200-07 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

4

1,800,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

38,298

10

Costs Broken Out 

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cos

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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: 6 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

Purchase Part - High Impact Item (Full Cost Mapping)

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin; Solenoid Plunger Pin Spacer; Solenoid 

Plunger Pin Seal

010705-N0200-07-01

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.16 $0.06 $0.22 $0.00 $0.01 $0.01 $0.00 $0.02 Assemble Solenoid Plunger Pin to Solenoid Plunger Pin Spacer & Solenoid Plunger Pin Seal 5 2 10 100 47 4700 383 9.40 85% 451 7.99 15 1 1 15 1.0 2.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! #DIV/0! 85% 0 #DIV/0! #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Solenoid Plunger Pin Assy: Solenoid Shell 010705-N0200-07-02

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin 010705-N0200-07-03

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin 010705-N0200-07-04

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin 010705-N0200-07-05

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin Spacer 010705-N0200-07-06

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin Seal 010705-N0200-07-07

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin Spacer 010705-N0200-07-08

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin Spacer 010705-N0200-07-09

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin Spacer 010705-N0200-07-10

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.26 $0.23 $0.49 $0.00 $0.03 $0.02 $0.00 $0.05 Drill IDs, Bore IDs, Chamfers; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 40 1 1 40 1.0 5.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.06 $0.13 $0.18 $0.00 $0.01 $0.01 $0.00 $0.03 Grind ODs; operator load & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 10 1 1 10 1.0 2.0

$0.23 $0.24 $0.47 $0.00 $0.03 $0.02 $0.00 $0.05 Drill IDs, Bore IDs, Chamfers; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 42 1 1 42 1.0 6.0

$0.09 $0.26 $0.36 $0.00 $0.02 $0.02 $0.00 $0.05 500 Ton Hot Forge w/ automated mat'l hdlg; operator cycles 5 2 10 100 47 4700 383 9.40 85% 451 7.99 8 1 1 8 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.23 $0.20 $0.43 $0.00 $0.03 $0.02 $0.00 $0.04 Drill IDs, Bore IDs, Chamfers; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 35 1 1 35 1.0 5.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 55-150 Ton Mold Solenoid Plunger Pin Seal; operator cycle operation 5 2 10 100 47 4700 383 9.40 85% 451 7.99 7 1 14 7 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 383 9.40 85% 451 7.99 13 1 30 13 1.0 1.0

$0.07 $0.15 $0.23 $0.00 $0.01 $0.01 $0.00 $0.02 Heat treat Solenoid Plunger Pin Spacer; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 11 1 1 11 1.0 2.0

$0.02 $0.11 $0.13 $0.00 $0.01 $0.01 $0.00 $0.01 Apply plating to Solenoid Plunger Pin Spacer; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 8 1 2 8 1.0 1.0

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin 010705-N0200-07-11

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin 010705-N0200-07-12

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin 010705-N0200-07-13

Solenoid Plunger Pin Assy: Solenoid Shell 010705-N0200-07-14

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 383 9.40 85% 451 7.99 13 1 30 13 1.0 1.0

$0.07 $0.14 $0.21 $0.00 $0.01 $0.01 $0.00 $0.02 Heat treat Solenoid Plunger Pin; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 10 1 1 10 1.0 2.0

$0.02 $0.11 $0.13 $0.00 $0.01 $0.01 $0.00 $0.01 Apply plating to Solenoid Plunger Pin; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 8 1 2 8 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.01 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 383 9.40 85% 451 7.99 13 1 20 13 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: 8 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Solenoid Plunger Pin Assy: Solenoid Shell 010705-N0200-07-15

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.06 $0.28 $0.33 $0.00 $0.02 $0.01 $0.00 $0.03 Apply plating to Solenoid Shell; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 10 1 1 10 1.0 2.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $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 - Commodity ( Value taken from Purchase Part Database)

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$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

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$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

$1.27 $1.91 $3.19 $0.01 $0.19 $0.14 $0.01 $0.35

$3.54

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: 10 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

File: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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin; Solenoid Plunger Pin Spacer; Solenoid 

Plunger Pin Seal

010705-N0200-07-01

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

480 7.50 2.00

#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! -

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Solenoid Plunger Pin Assy: Solenoid Shell 010705-N0200-07-02

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin 010705-N0200-07-03

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin 010705-N0200-07-04

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin 010705-N0200-07-05

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin Spacer 010705-N0200-07-06

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin Seal 010705-N0200-07-07

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin Spacer 010705-N0200-07-08

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin Spacer 010705-N0200-07-09

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin Spacer 010705-N0200-07-10

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

450 8.00 3.00

#DIV/0! #DIV/0! -

720 5.00 1.00

514 7.00 3.00

450 8.00 1.00

#DIV/0! #DIV/0! -

514 7.00 3.00

#DIV/0! #DIV/0! -

7200 0.50 0.25

8308 0.43 0.25

655 5.50 1.00

900 4.00 0.50

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin 010705-N0200-07-11

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin 010705-N0200-07-12

Solenoid Plunger Pin Assy: Solenoid Plunger 

Pin 010705-N0200-07-13

Solenoid Plunger Pin Assy: Solenoid Shell 010705-N0200-07-14

#DIV/0! #DIV/0! -

8308 0.43 0.25

720 5.00 1.00

900 4.00 0.50

#DIV/0! #DIV/0! -

5538 0.65 0.25

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 13 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Solenoid Plunger Pin Assy: Solenoid Shell 010705-N0200-07-15

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

720 5.00 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! -

Purchase Part - Commodity ( Value taken from Purchase Part Database)

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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: 14 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 15 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Electrical Assembly Part Number: 010705-N0200-08 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

38,298

10

North America

North America

FOB Ship Point

47

450,000

4

1,800,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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

Electrical Assembly: Bobbin Assembly; Bobbin 

Spacer 010705-N0200-08-01 1

Load Bobbin Assembly & 

Bobbin Spacer into Mold 

Cavities & Overmold parts

T2/T3 Inject. Mold, SSLC PBT-GF20, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS 576 1 1 1 0.030 $1.46 $41.48 $16.39 $16.39 $0.04 $0.07 $0.03 $0.14 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.16 $0.16 $0.04

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 FM Bobbin Assembly: Bobbin; Bobbin Wire 010705-N0200-08-02 1

Assemble Bobbin by wrapping 3 FM Bobbin Assembly: Bobbin; Bobbin Wire 010705-N0200-08-02 1 T2/T3 Elect. Assembly, SSLC Copper - Windings, <1mm Electromechanical Assembly Elec. Assembly, MHC, Base 450 3 3 1 0.110 $2.94 $36.21 $45.00 $135.00 $0.32 $0.24 $0.30 $0.86 0.30% 6.00% 4.00% 0.00% 10.30% $0.09 $0.95 $0.95 $0.32 Assemble Bobbin by wrapping 

w/ Bobbin Wire T2/T3 Elect. Assembly, SSLC Copper - Windings, <1mm Electromechanical Assembly Elec. Assembly, MHC, Base 450 3 3 1 0.110 $2.94 $36.21 $45.00 $135.00 $0.32 $0.24 $0.30 $0.86 0.30% 6.00% 4.00% 0.00% 10.30% $0.09 $0.95 $0.95 $0.32

4 FM Bobbin Assembly: Bobbin Terminals 010705-N0200-08-03 1

Assemble Bobbin Terminals to 

Bobbin Sub-Assy T2/T3 Elect. Assembly, SSLC Not Applicable Electromechanical Assembly Elec. Assembly, LC, Base 480 2 2 1 0.000 $0.00 $36.21 $15.00 $30.00 $0.00 $0.15 $0.06 $0.21 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.24 $0.24 $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

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:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Electrical Assembly Part Number: 010705-N0200-08 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

38,298

10

North America

North America

FOB Ship Point

47

450,000

4

1,800,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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

31 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

32 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

33 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

34 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

35 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

36 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

37 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

38 Electrical Assembly: Bobbin Spacer 010705-N0200-08-04 1 CNC Turning T2/T3 CNC Turning, SSLC MC-Steel-1018, Bar Lathe/Turning Operator CNC Turning, SS, BF, DA 514 3 7 1 0.070 $0.74 $38.97 $20.48 $143.36 $0.05 $0.23 $0.28 $0.56 0.30% 6.00% 4.00% 0.00% 10.30% $0.06 $0.62 $0.62 $0.05

39 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

40 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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 Electrical Assembly: Bobbin Spacer 010705-N0200-08-05 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 8308 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.00 $0.00 $0.00

2 Electrical Assembly: Bobbin Spacer 010705-N0200-08-06 1 DeBurr T2/T3 Mech. Assembly, SSLC Not Applicable Grinding/Polishing Operator Washing Equipment, LMC 514 1 2 1 0.000 $0.00 $42.14 $20.81 $41.62 $0.00 $0.08 $0.08 $0.16 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.18 $0.18 $0.00

3 Electrical Assembly: Bobbin Spacer 010705-N0200-08-07 1 Plating T2/T3 Plate/Finish Elect., SSLC Not Applicable Plating/Coating Operator Plate Elect., SMS, LMC 800 0.5 1 1 0.000 $0.00 $40.84 $100.18 $100.18 $0.00 $0.03 $0.13 $0.15 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.17 $0.17 $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

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:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Electrical Assembly Part Number: 010705-N0200-08 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

38,298

10

North America

North America

FOB Ship Point

47

450,000

4

1,800,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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

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 FM Bobbin 010705-N0200-08-08 1 (qtys applied on CMAT) S $0.00 $0.10 $0.00 $0.10 $0.10

2 0 $0.00 $0.00 $0.00 $0.00 $0.00

3 FM Bobbin Terminals 010705-N0200-08-09 2 (qtys applied on CMAT) S $0.00 $0.03 $0.00 $0.06 $0.06

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

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

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

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

31 0 $0.00 $0.00 $0.00 $0.00 $0.00

32 0 $0.00 $0.00 $0.00 $0.00 $0.00

33 0 $0.00 $0.00 $0.00 $0.00 $0.00

34 0 $0.00 $0.00 $0.00 $0.00 $0.00

35 0 $0.00 $0.00 $0.00 $0.00 $0.00

36 0 $0.00 $0.00 $0.00 $0.00 $0.00

37 0 $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: 4 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Electrical Assembly Part Number: 010705-N0200-08 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS Manufacturing Cos

Costs Broken Out 

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS TOTAL COSTS TOOLING & INVESTMENT

38,298

10

North America

North America

FOB Ship Point

47

450,000

4

1,800,000

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

38 0 $0.00 $0.00 $0.00 $0.00 $0.00

39 0 $0.00 $0.00 $0.00 $0.00 $0.00

40 0 $0.00 $0.00 $0.00 $0.00 $0.00

41 0 $0.00 $0.00 $0.00 $0.00 $0.00

42 0 $0.00 $0.00 $0.00 $0.00 $0.00

43 0 $0.00 $0.00 $0.00 $0.00 $0.00

44 0 $0.00 $0.00 $0.00 $0.00 $0.00

45 0 $0.00 $0.00 $0.00 $0.00 $0.00

46 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$0.58

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $2.47

T1 or OEM Total Manufacturing Cost: $0.58 $0.80 $0.88 $2.26 $0.01 $0.13 $0.08 $0.00 $0.22 $2.47

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.01 $0.16 $0.15 $0.06 $0.38

Base Cost Impact to Vehicle: $0.58 $0.80 $0.88 $2.26 $0.02 $0.29 $0.23 $0.06 $0.60 $2.86 $0 $0

Packaging Cost: $0.00

Net Cost Impact to Vehicle: $2.86

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.000 $0 0.00% 9,000,000 60 5.00% $0 230 1000 6 229787

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:

3

1

Notes: 

a) Items 1,2, & 3 mus

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: 5 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern Minimum Calculated Cycles Time 

Purchase Part - High Impact Item (Full Cost Mapping)

Electrical Assembly: Bobbin Assembly; Bobbin 

Spacer 010705-N0200-08-01

FM Bobbin Assembly: Bobbin; Bobbin Wire 010705-N0200-08-02

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.07 $0.03 $0.14 $0.00 $0.01 $0.01 $0.00 $0.01 55-150 Ton Mold Electrical Assembly; operator load parts into mold cavities & cycle operation 

(used PBT-GF20, Inject. Material due to PBT-GF30, Inject. Not available on RM database) 5 2 10 100 47 4700 383 9.40 85% 451 7.99 25 1 4 25 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

FM Bobbin Assembly: Bobbin; Bobbin Wire 010705-N0200-08-02 $0.24 $0.30 $0.86 $0.00 $0.05 $0.03 $0.00 $0.09 Assemble Bobbin by wrapping w/ Bobbin Wire. Automated winding station, auto load and clamp, cut and position leads. 5 2 10 100 47 4700 383 9.40 85% 451 7.99 24 1 1 24 1.0 3.0

FM Bobbin Assembly: Bobbin Terminals 010705-N0200-08-03

$0.24 $0.30 $0.86 $0.00 $0.05 $0.03 $0.00 $0.09 Assemble Bobbin by wrapping w/ Bobbin Wire. Automated winding station, auto load and clamp, cut and position leads. 5 2 10 100 47 4700 383 9.40 85% 451 7.99 24 1 1 24 1.0 3.0

$0.15 $0.06 $0.21 $0.00 $0.01 $0.01 $0.00 $0.02 Assemble Bobbin Terminals (2x) to Bobbin Sub-Assy 5 2 10 100 47 4700 383 9.40 85% 451 7.99 15 1 1 15 1.0 2.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $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:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern 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

Electrical Assembly: Bobbin Spacer 010705-N0200-08-04

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Electrical Assembly: Bobbin Spacer 010705-N0200-08-05

Electrical Assembly: Bobbin Spacer 010705-N0200-08-06

Electrical Assembly: Bobbin Spacer 010705-N0200-08-07

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.23 $0.28 $0.56 $0.00 $0.03 $0.02 $0.00 $0.06 Drill & Bore IDs, Drill Thru holes; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 49 1 1 49 1.0 7.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 383 9.40 85% 451 7.99 13 1 30 13 1.0 1.0

$0.08 $0.08 $0.16 $0.00 $0.01 $0.01 $0.00 $0.02 Deburring Bobbin Spacer; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 14 1 1 14 1.0 2.0

$0.03 $0.13 $0.15 $0.00 $0.01 $0.01 $0.00 $0.02 Apply plating to Bobbin Spacer; operator load/unload & cycle 5 2 10 100 47 4700 383 9.40 85% 451 7.99 9 1 2 9 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! #DIV/0! 85% 0 #DIV/0! #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 7 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern 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

Purchase Part - Commodity ( Value taken from Purchase Part Database)

FM Bobbin 010705-N0200-08-08

FM Bobbin Terminals 010705-N0200-08-09

$0.10

$0.00

$0.06

$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

$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: 8 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Gross Mark-up Costs x Quantity Process Information Project Process Requirement

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern Minimum Calculated Cycles Time 

$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

$0.80 $0.88 $2.26 $0.01 $0.13 $0.08 $0.00 $0.22

$2.47

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: 9 of 12 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

Electrical Assembly: Bobbin Assembly; Bobbin 

Spacer 010705-N0200-08-01

FM Bobbin Assembly: Bobbin; Bobbin Wire 010705-N0200-08-02

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

576 6.25 1.00

#DIV/0! #DIV/0! -

FM Bobbin Assembly: Bobbin; Bobbin Wire 010705-N0200-08-02 450 8.00 3.00

FM Bobbin Assembly: Bobbin Terminals 010705-N0200-08-03

450 8.00 3.00

480 7.50 2.00

#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:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Electrical Assembly: Bobbin Spacer 010705-N0200-08-04

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Electrical Assembly: Bobbin Spacer 010705-N0200-08-05

Electrical Assembly: Bobbin Spacer 010705-N0200-08-06

Electrical Assembly: Bobbin Spacer 010705-N0200-08-07

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

514 7.00 3.00

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

8308 0.43 0.25

514 7.00 1.00

800 4.50 0.50

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - Commodity ( Value taken from Purchase Part Database)

FM Bobbin 010705-N0200-08-08

FM Bobbin Terminals 010705-N0200-08-09

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:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File: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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Cover Plate Assy Part Number: 010705-N0200-09 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

A Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #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

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

9,574

10

Costs Broken Out 

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cos

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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

Solenoid Cover Plate Assy: Solenoid Cover 

Base Plate; Solenoid Cover Check Valve 010705-N0200-09-01 1

Assemble Solenoid Cover 

Check Valves into Base Plate - 

press together

T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 400 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.05 $0.04 $0.09 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.09 $0.09 $0.00

2

Solenoid Cover Plate Assy: Solenoid Cover 

Plate Gasket; Solenoid Cover Plate 010705-N0200-09-02 1

Assemble Solenoid Cover Plate 

2 Gasket & Solenoid Cover Plate T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 277 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.07 $0.05 $0.12 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.14 $0.14 $0.00 Plate Gasket; Solenoid Cover Plate 010705-N0200-09-02 1 Gasket & Solenoid Cover Plate 

to Base Plate

T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base 277 0.5 1 1 0.000 $0.00 $38.55 $15.00 $15.00 $0.00 $0.07 $0.05 $0.12 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.14 $0.14 $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

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Cover Plate Assy Part Number: 010705-N0200-09 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

9,574

10

Costs Broken Out 

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cos

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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

31 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

32 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

33 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

34 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

35 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

36 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

37 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

38 Solenoid Cover Plate Assy: Solenoid Cover 

Base Plate 010705-N0200-09-03 1 CNC Machining T2/T3 CNC Milling, MSMC Not Applicable CNC Operator CNC Machining, LMC 116 1 2 1 0.000 $0.00 $36.98 $34.48 $68.96 $0.00 $0.32 $0.59 $0.91 0.50% 6.50% 6.00% 1.00% 14.00% $0.13 $1.04 $1.04 $0.00

39 0 ##### 0 1 1 0.000 #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A $0.00 $0.00

40 Solenoid Cover Plate Assy: Solenoid Cover 

Plate Gasket Matl; Solenoid Cover Plate 010705-N0200-09-04 1 Apply Gasket Bead T2/T3 Inject. Mold, SSLC Permatex Mold/Cast/Sinter Operator Inject. Mold, SS 200 0.5 1 1 0.003 $12.00 $41.48 $16.39 $16.39 $0.03 $0.10 $0.08 $0.22 0.30% 6.00% 4.00% 0.00% 10.30% $0.02 $0.24 $0.24 $0.03

C Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1

Solenoid Cover Plate Assy: Solenoid Cover 

Plate Gasket 010705-N0200-09-05 1 Stamp Press T2/T3 Stamp/Form, LSHC PMP Cut/Punch/Forming Operator Stamp/Form, SS 1800 0.25 1 1 0.098 $0.70 $42.73 $42.91 $42.91 $0.07 $0.01 $0.02 $0.10 0.70% 7.00% 8.00% 2.00% 17.70% $0.02 $0.12 $0.12 $0.07

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

Solenoid Cover Plate Assy: Solenoid Cover 

Plate 010705-N0200-09-06 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 8308 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.00 $0.00 $0.00 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.00 $0.00 $0.00

6

Solenoid Cover Plate Assy: Solenoid Cover 

Plate 010705-N0200-09-07 1 Stamp Press T2/T3 Stamp/Form, LSHC LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, XSS 1800 0.25 1 1 0.338 $0.48 $42.73 $24.60 $24.60 $0.16 $0.01 $0.01 $0.18 0.70% 7.00% 8.00% 2.00% 17.70% $0.03 $0.21 $0.21 $0.16

7

Solenoid Cover Plate Assy: Solenoid Cover 

Plate 010705-N0200-09-08 1 ID Etch T2/T3 CNC Milling, SSLC Not Applicable CNC Operator CNC Machining, LC 360 0.5 1 1 0.000 $0.00 $36.98 $30.38 $30.38 $0.00 $0.05 $0.08 $0.14 0.30% 6.00% 4.00% 0.00% 10.30% $0.01 $0.15 $0.15 $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

Solenoid Cover Plate Assy: Solenoid Cover 

Base Plate 010705-N0200-09-09 1 Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LMC 1662 0.25 1 1 0.000 $0.00 $38.55 $20.81 $20.81 $0.00 $0.01 $0.01 $0.02 0.30% 6.00% 4.00% 0.00% 10.30% $0.00 $0.02 $0.02 $0.00

10 Solenoid Cover Plate Assy: Solenoid Cover 

Base Plate 010705-N0200-09-10 1 Stamp Press T2/T3 Stamp/Form, LSHC Aluminum-3003, Coil A Cut/Punch/Forming Operator Stamp/Form, XSS 1800 0.25 1 1 1.212 $1.41 $42.73 $24.60 $24.60 $1.71 $0.01 $0.01 $1.73 0.70% 7.00% 8.00% 2.00% 17.70% $0.31 $2.03 $2.03 $1.71

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

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Cover Plate Assy Part Number: 010705-N0200-09 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

9,574

10

Costs Broken Out 

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cos

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

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

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 FM Solenoid Cover Check Valve 010705-N0200-09-11 1 S $0.00 $0.12 $0.00 $0.12 $0.12

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

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

"S"=Indicates Component is Supplied directly to T1 or OEM for Final or SubAssembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to 

T1 or OEM for Final or Sub-Assembly. In addition component material cost is 

accounted for in T1 quote sheet. Thus component cost will only be included for 

Mark-up Calculations.

"Alpha-Numeric Character" = Indicates purchase parts are brought in by T2/T3 

Supplier for Subassembly.

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

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Cover Plate Assy Part Number: 010705-N0200-09 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

9,574

10

Costs Broken Out 

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cos

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

31 0 $0.00 $0.00 $0.00 $0.00 $0.00

32 0 $0.00 $0.00 $0.00 $0.00 $0.00

33 0 $0.00 $0.00 $0.00 $0.00 $0.00

34 0 $0.00 $0.00 $0.00 $0.00 $0.00

35 0 $0.00 $0.00 $0.00 $0.00 $0.00

36 0 $0.00 $0.00 $0.00 $0.00 $0.00

37 0 $0.00 $0.00 $0.00 $0.00 $0.00

38 0 $0.00 $0.00 $0.00 $0.00 $0.00

39 0 $0.00 $0.00 $0.00 $0.00 $0.00

40 0 $0.00 $0.00 $0.00 $0.00 $0.00

41 0 $0.00 $0.00 $0.00 $0.00 $0.00

42 0 $0.00 $0.00 $0.00 $0.00 $0.00

43 0 $0.00 $0.00 $0.00 $0.00 $0.00

44 0 $0.00 $0.00 $0.00 $0.00 $0.00

45 0 $0.00 $0.00 $0.00 $0.00 $0.00

46 0 $0.00 $0.00 $0.00 $0.00 $0.00

Material

$2.09

Material Labor Burden TMC Scrap SG&A Profit ED&T Total 

Mark-up $4.17

T1 or OEM Total Manufacturing Cost: $2.09 $0.62 $0.92 $3.62 $0.02 $0.23 $0.24 $0.05 $0.54 $4.17

T1 or OEM Mark-Up Rates: ----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

(SAC) &T1 or OEM Mark-Up Values: 0.00 ----- ----- ----- $0.02 $0.27 $0.25 $0.10 $0.65

Base Cost Impact to Vehicle: $2.09 $0.62 $0.92 $3.62 $0.04 $0.51 $0.49 $0.15 $1.19 $4.81 $0 $0

Packaging Cost: $0.02

Net Cost Impact to Vehicle: $4.84

Packaging 

Cost per 

Piece

Total 

Amount

Lump Sum 

Payment 

(%)

Total # of 

Pieces

Number of 

Months

Interest 

Rate

Cost per Pallet /Rack

Total Number of Pallets/

Racks Required

Number of Parts per Pallet/

Rack

Supplier, Customer and Intransit Inventory

Requirements (Weeks)

Supplier, Customer and Intransit Inventory

Requirements (Parts)

Rack/Pallet Investment Amortization: $0.024 $48,000 0.00% 2,250,000 60 5.00% $800 60 960 6 57447

PACKAGING CALCULATIONS: 

Packaging Type: Option #1

Part Size: 15"L x 4"W x 1"H

Parts/Layer: 32

Number of Layers: 30

3

1

Notes: 

a) Items 1,2, & 3 mus

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

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: $0.024

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level: OEM Operating Pattern (Weeks/Year): OEM Plant Location:

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers Annual Engine Volume (CPV): Supplier Plant Location:

Study Case#: N0200 (N=New, 02=Multi-Air, 00=Subcompact Vehicle Class) Components per Engine: OEM/T1 Classification: T1 Moderate Assembly Complexity

System Description: 2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine Annual Component Volume: Shipping Method:

Component Description: FM Solenoid Cover Plate Assy Part Number: 010705-N0200-09 Weekly Component Volume: Packaging Specification: Returnable Dunnage

Component Quote Level: Estimated Product Life: Production Year: 2008/2009

Item 

Reference #

Part Description Part Number

QTY Per Assembly

Primary Process 

Description

OEM/Supplier 

Classification

Material 

Specification

Labor 

Classification

Burden

Classification

Finished Pieces Per Hour

Number of Operators

Number of Lines

Parallel Processing

Multiplier

Material Usage "lbs"

Material 

Cost 

$/lb

(DB)

Labor 

Rate

$/Hour

(DB)

Burden 

Rate

$/Hour

(DB)

Applied 

Burden 

Rate 

$/Hour

Material 

Cost Labor/ Part Burden/ Part

Total 1 =

Material + Labor + Burden

End 

Item 

Scrap 

Rate

(DB)

SG&A 

Rate

(DB)

Profit 

Rate

(DB)

ED&T/ 

R&D 

Rate

(DB)

Total 

Markup 

Rate

Total 

Markup 

Cost

Total 2 =

Total 1 + Total Mark-up

Total 3 =

Total 2 * Qty per Ass'y

Tooling Assumptions

"x1000 "

Investment Assumptions

"x1000 "

Material

North America

North America

FOB Ship Point

47

450,000

1

450,000

GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION MANUFACTURING RATES MANUFACTURING COSTS

Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

MARK-UP COSTS

9,574

10

Costs Broken Out 

TOTAL COSTS TOOLING & INVESTMENT Manufacturing Cos

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Full Quote Modification Quote Differential Quote (Quote Summary includes costing for both Technology Packages)

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 6 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

Purchase Part - High Impact Item (Full Cost Mapping)

Solenoid Cover Plate Assy: Solenoid Cover 

Base Plate; Solenoid Cover Check Valve 010705-N0200-09-01

Solenoid Cover Plate Assy: Solenoid Cover 

Plate Gasket; Solenoid Cover Plate 010705-N0200-09-02

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.05 $0.04 $0.09 $0.00 $0.01 $0.00 $0.00 $0.01 Assemble Solenoid Cover Check Valve into Base Plate - press together w/ tool assist 5 2 10 100 47 4700 96 37.60 85% 113 31.96 9 1 1 9 1.0 1.0

$0.07 $0.05 $0.12 $0.00 $0.01 $0.00 $0.00 $0.01 Assemble Solenoid Cover Plate Gasket & Solenoid Cover Plate to Base Plate & stake (2X) in place 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0 Plate Gasket; Solenoid Cover Plate 010705-N0200-09-02 $0.07 $0.05 $0.12 $0.00 $0.01 $0.00 $0.00 $0.01 Assemble Solenoid Cover Plate Gasket & Solenoid Cover Plate to Base Plate & stake (2X) in place 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 1 13 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Solenoid Cover Plate Assy: Solenoid Cover 

Base Plate 010705-N0200-09-03

Solenoid Cover Plate Assy: Solenoid Cover 

Plate Gasket Matl; Solenoid Cover Plate 010705-N0200-09-04

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Solenoid Cover Plate Assy: Solenoid Cover 

Plate Gasket 010705-N0200-09-05

Solenoid Cover Plate Assy: Solenoid Cover 

Plate 010705-N0200-09-06

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.32 $0.59 $0.91 $0.00 $0.06 $0.05 $0.01 $0.13 Drill holes, machine channel; operator cycle 5 2 10 100 47 4700 96 37.60 85% 113 31.96 62 1 1 62 1.0 2.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.10 $0.08 $0.22 $0.00 $0.01 $0.01 $0.00 $0.02 Apply Permatex gasket bead material to cover plate groove profile; operator load/unload & cycle operation 

(used Permatex @ $12/lb due to no other mat'l in RM database.) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 18 1 1 18 1.0 1.0

$0.01 $0.02 $0.10 $0.00 $0.01 $0.01 $0.00 $0.02 200-400 Ton Stamping Press w/ progressive die for Solenoid Cover Plate Gasket; operator cycle controls 

(PMP used @$0.70/lb - not on RM database) 5 2 10 100 47 4700 96 37.60 85% 113 31.96 2 1 1 2 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 30 13 1.0 1.0

Solenoid Cover Plate Assy: Solenoid Cover 

Plate 010705-N0200-09-07

Solenoid Cover Plate Assy: Solenoid Cover 

Plate 010705-N0200-09-08

Solenoid Cover Plate Assy: Solenoid Cover 

Base Plate 010705-N0200-09-09

Solenoid Cover Plate Assy: Solenoid Cover 

Base Plate 010705-N0200-09-10

$0.01 $0.01 $0.18 $0.00 $0.01 $0.01 $0.00 $0.03 60-200 Ton Stamping Press w/ progressive die for Solenoid Cover Plate; operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 2 1 1 2 1.0 1.0

$0.05 $0.08 $0.14 $0.00 $0.01 $0.01 $0.00 $0.01 Laser etch part ID (3 lines & symbol); operator load/unload & cycle 5 2 10 100 47 4700 96 37.60 85% 113 31.96 10 1 1 10 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.01 $0.01 $0.02 $0.00 $0.00 $0.00 $0.00 $0.00 In-line turbo washer w/ conveyor, operator load/unload 5 2 10 100 47 4700 96 37.60 85% 113 31.96 13 1 6 13 1.0 1.0

$0.01 $0.01 $1.73 $0.01 $0.12 $0.14 $0.03 $0.31 60-200 Ton Stamping Press w/ progressive die for Solenoid Cover Plate; operator cycle controls 5 2 10 100 47 4700 96 37.60 85% 113 31.96 2 1 1 2 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $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: 8 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

Purchase Part - Commodity ( Value taken from Purchase Part Database)

FM Solenoid Cover Check Valve 010705-N0200-09-11

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 5 2 10 100 47 4700 0 #DIV/0! 85% 0 #DIV/0! - - - - 1.0 1.0

$0.12

$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

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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$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

$0.62 $0.92 $3.62 $0.02 $0.23 $0.24 $0.05 $0.54

$4.17

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: 10 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Labor Burden

Total Mfg'ing Cost

(Component/ Assembly)

End Item 

Scrap SG&A Profit ED&TR&D

Total Markup Cost

(Component/ Assembly)

Process & Equipment Assumptions Tool, Fixture and Gauge Assumptions Days/

Week

Shifts./ 

Day

Hrs./ 

Shift

Hrs./ 

Wk

Wks./ 

Yr.

Hrs./ 

Yr.

Pcs../ Hr. (100% Eff..)

Cycle Time/Operation

"Sec."

Efficiency %

Pcs../ Hr.

@ Stated Efficiency

Cycle Time/Operation @

Stated Efficiency "Sec."

Lean Design Calculation

for Complete Process

Time "Sec."

Parallel

Operations/Machine or

Stations/Line

Piece/Cycle/Machine

Tack Time/Machine/Cycle

"Seconds"

Multiplier, If Required for

Parallel Processing

(1=Nothing)

Number of Equivalent

Machines Required

Gross Mark-up Costs x Quantity Process Information

Costs Broken Out Into Categories with Quantity per Assembly Taken into Account

Projected Operating Pattern

MANUFACTURING ASSUMPTIONS

Manufacturing Costs x Quantity Minimum Calculated Cycles Time Project Process Requirement

File: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 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - High Impact Item (Full Cost Mapping)

Solenoid Cover Plate Assy: Solenoid Cover 

Base Plate; Solenoid Cover Check Valve 010705-N0200-09-01

Solenoid Cover Plate Assy: Solenoid Cover 

Plate Gasket; Solenoid Cover Plate 010705-N0200-09-02

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

400 9.00 0.50

277 13.00 0.50 Plate Gasket; Solenoid Cover Plate 010705-N0200-09-02 277 13.00 0.50

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#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: 12 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Solenoid Cover Plate Assy: Solenoid Cover 

Base Plate 010705-N0200-09-03

Solenoid Cover Plate Assy: Solenoid Cover 

Plate Gasket Matl; Solenoid Cover Plate 010705-N0200-09-04

Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

Solenoid Cover Plate Assy: Solenoid Cover 

Plate Gasket 010705-N0200-09-05

Solenoid Cover Plate Assy: Solenoid Cover 

Plate 010705-N0200-09-06

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

116 31.00 1.00

#DIV/0! #DIV/0! -

200 18.00 0.50

1800 2.00 0.25

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

8308 0.43 0.25

Solenoid Cover Plate Assy: Solenoid Cover 

Plate 010705-N0200-09-07

Solenoid Cover Plate Assy: Solenoid Cover 

Plate 010705-N0200-09-08

Solenoid Cover Plate Assy: Solenoid Cover 

Base Plate 010705-N0200-09-09

Solenoid Cover Plate Assy: Solenoid Cover 

Base Plate 010705-N0200-09-10

1800 2.00 0.25

360 10.00 0.50

#DIV/0! #DIV/0! -

1662 2.17 0.25

1800 2.00 0.25

#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: 13 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

#DIV/0! #DIV/0! -

Purchase Part - Commodity ( Value taken from Purchase Part Database)

FM Solenoid Cover Check Valve 010705-N0200-09-11

#DIV/0! #DIV/0! -

#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: 14 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
Page: 15 of 15 Manufacturing Assumption and Quote Summary Print Date:8/23/2012

DRAFT

Technology Level:

Vehicle Class:

Study Case#:

System Description:

Component Description:

Component Quote Level:

Reference #

Part Description Part Number

GENERAL COMPONENT INFORMATION

1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

Resulting Pieces/Hour

Resulting Cycle Time/

Part

"Sec.

Total Number of Direct

Operators

File:09000064810e7549.xls

EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Form Author: G. Kolwich

(248)373-6000 Ext. 2411
07 Valvetrain Subsystem QTY $$$

o FM Multi-Air System 1

o FM Solenoid Housing Gasket 1

o A FM Solenoid Housing Assy 1

o B FM Solenoid Housing 1

o FM Oil Return Check Valve 4

0 FM Solenoid Check Valve 1

o FM Solenoid Housing Ball Stop 2

o FM Solenoid Housing Ball Stop 1

o FM Solenoid Housing Cup Stop 1

o FM Solenoid Housing Ball Stop 1

o FM Rocker Pin 4

o FM Rocker Piston Bore 4

o FM Rocker Piston Assy 4

o FM Rocker Piston, Shaft 4

o FM Rocker Piston Cup 4

o FM Rocker Piston, Clip 4

o FM Rocker Spring 4

o FM Roller Rocker 4

o FM Pressure Relief O-Ring 4

o FM Pressure Relief Piston 4

o FM Pressure Relief Spring 4

o FM Pressure Relief Spring Seat 4

o FM Pressure Relief Clip 4

o FM Check Valve 8

o C FM Valve Actuation Piston Assy 8

o FM Valve Actuation Piston, Cap 8

o FM Valve Actuation Piston, Clip 8

o FM Valve Actuation Piston, Long Pin 8

o FM Valve Actuation Piston, Spring Guide 8

o FM Valve Actuation Piston, Spring 8

o FM Valve Actuation Piston, Housing 8

o FM Valve Actuation Piston, Short Pin 8

o FM Valve Actuation Piston, Yellow O-Ring 8

o FM Valve Actuation Piston, Black O-Ring 8

o D FM Oil Control Solenoid Assy 4

o FM Label, Solenoid 4

o FM Solenoid Plunger Assy 4

o FM Solenoid Plunger Housing 4

o FM Solenoid Plunger Stop 4

o E FM Solenoid Plunger SubAssy 4

o FM Solenoid Plunger Frame 4

o FM Solenoid Plunger Frame Piston Stop 4

o FM Solenoid Plunger Piston Assy 4

o FM Solenoid Plunger Piston Body 4

O FM Solenoid Plunger Piston Body Shaft 4

o FM Solenoid Plunger Piston Spring 4
o FM Solenoid Plunger Piston Body Assy 4

o FM Solenoid Plunger Piston Body Assy, Body 4

o FM Solenoid Plunger Piston Body Assy, Insert 4

o F FM Solenoid Plunger Pin Assy 4

o FM Solenoid Plunger Pin 4

o FM Solenoid Plunger Pin Spacer 4

o FM Solenoid Plunger Pin Seal 4

o FM Solenoid Plunger Spring, Large 4

o FM Solenoid Plunger Spring, Small 4

o FM Solenoid Plunger Nose Piece 4

o F FM Solenoid Shell 4

o G FM Electrical Assembly 4

o FM Bobbin Assembly 4

o FM Bobbin 4

o FM Bobbin Wire 4

o FM Bobbin Terminals 8

o FM Bobbin Spacer 4

o FM Oil Temp Sensor 1

o FM Primary Oil Feed O-Ring, Center Hsg 1

o FM Solenoid Housing Bolt 9

o H FM Solenoid Cover Plate Assy 1

o FM Solenoid Cover Base Plate 1

o FM Solenoid Cover Base Plate Gasket Matl 1

o FM Solenoid Cover Check Valve 1

o FM Solenoid Cover Plate Gasket 1

0 FM Solenoid Cover Plate 1

o FM Solenoid Cover Plate Bolt 18

Total # Pcs: 309






617 0
Comments $/pc

$

Top Level PMAP ID

PMAP

PMAP

PMAP

Commodity 0.1 0.4

Commodity 0.12 0.12

Commodity 0.04 0.08

Commodity 0.04 0.04

Commodity 0.02 0.02

Commodity 0.04 0.04

PMAP

PMAP

PMAP

PMAP

PMAP

Commodity 0.02 0.08

Commodity 0.23 0.92

Commodity 2.66 10.64

Commodity 0.04 0.16

PMAP

Commodity 0.07 0.28

PMAP

Commodity 0.01 0.04

Commodity 0.12 0.96

PMAP

PMAP

Commodity 0.02 0.16

PMAP

PMAP

Commodity 0.01 0.08

PMAP

PMAP

Commodity 0.04 0.32

Commodity 0.04 0.32

PMAP

Commodity 0.05 0.2

PMAP

PMAP

PMAP

PMAP

PMAP

PMAP

PMAP

PMAP

PMAP

Commodity 0.01 0.04
PMAP

PMAP

PMAP

PMAP

PMAP

PMAP

PMAP

Commodity 0.01 0.04

Commodity 0.01 0.04

PMAP

PMAP

PMAP

PMAP

Commodity 0.1 0.4

Commodity 0.12 0.48

Commodity 0.03 0.24

PMAP

Commodity 3.5 3.5

Commodity 0.04 0.04

Commodity 0.06 0.54

PMAP

PMAP

PMAP 0.03 0.03

Commodity 0.12 0.12

PMAP 0.07 0.07

PMAP

Commodity 0.03 0.54

Total $: 20.94
Indented Bill of Materials

FM Multi Air System

Level Symbol Name Number Qty Material Piece Cost Weight

FM Solenoid Housing Gasket FM Solenoid $0.09 Housing 

Gasket

1 FM Solenoid Housing Gasket FM Solenoid 1 PMP Plastic $0.09

Material Housing Gasket Metal Plastic

Material

0 FM Solenoid Housing Assy, FM Solenoid 1 $30.75

Tested Housing Assy, 

Tested

1 FM Solenoid Housing Assy FM Solenoid 1 $30.75

Housing Assy

2 FM Solenoid Housing, FM Solenoid 1 Aluminum - $10.69

Tested Housing, AlSi1MgMn 

Tested ##

3 FM Solenoid Housing, FM Solenoid 1 Aluminum - $10.69

Numbered Housing, AlSi1MgMn 

Numbered ##

4 FM Solenoid Housing, FM Solenoid Housing, FM Solenoid FM Solenoid 1 Aluminum - uminum - $10.69

Washed Housing, AlSi1MgMn 

Washed ##

5 FM Solenoid Housing, FM Solenoid 1 Aluminum - 

Machined Housing, AlSi1MgMn 

Machined ###

6 FM Solenoid Housing, FM Solenoid 1 Aluminum - 

Trimmed Housing, AlSi1MgMn 

Trimmed (6062)

7 FM Solenoid Housing, FM Solenoid 1 Aluminum - 

Forged Housing, AlSi1MgMn 

Forged ####

8 FM Solenoid Housing, Material FM Solenoid 1 Aluminum - 

Housing, AlSi1MgMn 

Material ####

2 FM Oil Return Check Valve FM Oil Return 4 Commodity $0.10

Check Valve Pricing

2 FM Solenoid Check Valve FM Solenoid 1 Commodity $0.12

Check Valve Pricing

Design Profit®

Page 1 of 13
Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Level Symbol Name Number Qty Material Piece Cost Weight

2 FM Solenoid Housing Ball Stop FM Solenoid 2 Commodity $0.04

Housing Ball Pricing

Stop

2 FM Solenoid Housing Ball Stop FM Solenoid 1 Commodity $0.04

Housing Ball Pricing

Stop

2 FM Solenoid Housing Cup FM Solenoid 1 Commodity $0.02

Stop Housing Cup Pricing

Stop

2 FM Solenoid Housing Ball Stop FM Solenoid 1 Commodity $0.04

Housing Ball Pricing

Stop

2 FM Rocker Pin FM Rocker Pin 4 $0.01

3 FM Rocker Pin Heat Treated FM Rocker Pin 1 Steel - 4037 $0.01

Heat Treated

4 FM Rocker Pin Washed FM Rocker Pin 1 Steel - 4037 $0.01

Washed

5 FM Rocker Pin Machined FM Rocker Pin 1 Steel - 4037

Machined1

6 FM Rocker Pin Blank FM Rocker Pin 1 Steel - 4037

Blank

7 FM Rocker Pin Material FM Rocker Pin 1 Steel - 4037

Material

2 FM Rocker Piston Bore FM Rocker 4 $0.12

Piston Bore

3 FM Rocker Piston Bore, FM Rocker 1 Steel 12L14 $0.12

Hardened Piston Bore, 

Hardened

4 FM Rocker Piston Bore, FM Rocker 1 Steel 12L14 $0.12

Washed Piston Bore, 

Washed

5 FM Rocker Piston Bore, FM Rocker 1 Steel 12L14

Machined Piston Bore, 

Machined

6 FM Rocker Piston Bore, FM Rocker 1 Steel 12L14

Material Piston Bore, 

Material

2 FM Rocker Piston FM Rocker 4 $0.10

Piston

3 FM Rocker Piston, Shaft FM Rocker 1 Steel - 4037 $0.07

Piston, Shaft

Design Profit®
Page 

2 of 13

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Level Symbol Name Number Qty Material Piece Cost

4 FM Rocker Piston, Shaft FM Rocker 1 Steel - 4037 $0.07

Washed Piston, Shaft 

Washed

5 FM Rocker Piston, Shaft FM Rocker 1 Steel - 4037

Machined Piston, Shaft 

Machined

6 FM Rocker Piston, Shaft FM Rocker 1 Steel - 4037

Blank Piston, Shaft 

Blank

7 FM Rocker Piston, Shaft Blank FM Rocker 1 Steel - 4037

Material Piston, Shaft 

Blank Material

3 FM Rocker Piston Cup FM Rocker 1 Steel 12L14 $0.01

Piston, Cup

4 FM Rocker Piston Cup, FM Rocker 1 Steel 12L14 $0.01

Stamped Piston Cup, 

Stamped

5 FM Rocker Piston Cup, FM Rocker 1 Steel 12L14

Material Piston Cup, 

Material

3 FM Rocker Piston, Clip FM Rocker 1 Commodity $0.02

Piston, Clip Pricing

2 FM Rocker Spring FM Rocker 4 Commodity $0.23

Spring Pricing

2 FM Roller Rocker FM Roller 4 Commodity $2.00

Rocker Pricing

2 FM Pressure Relief O-Ring FM Pressure 4 Commodity $0.04

Relief O-Ring Pricing

2 FM Pressure Relief Piston FM Pressure 4 $0.01

Relief Piston

3 FM Pressure Relief Piston, FM Pressure 1 Steel 12L14 $0.01

Hardened Relief Piston, 

Hardened

4 FM Pressure Relief Piston, FM Pressure 1 Steel 12L14 $0.01

Washed Relief Piston, 

Washed

5 FM Pressure Relief Piston, FM Pressure 1 Steel 12L14

Machined Relief Piston, 

Machined

6 FM Pressure Relief Piston, FM Pressure 1 Steel 12L14

Stamped Relief Piston, 

Stamped
Design Profit®

Page 3 of 13

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Level Symbol Name Number Qty Material Piece Cost

7 FM Pressure Relief Piston, FM Pressure 1 Steel 12L14

Material Relief Piston, 

Material

2 FM Pressure Relief Spring FM Pressure 4 Commodity $0.07

Relief Spring Pricing

2 FM Pressure Relief Spring FM Pressure 4 $0.01

Seat Relief Spring 

Seat

3 FM Pressure Relief Spring FM Pressure 1 Steel 12L14 $0.01

Seat, Hardened Relief Spring 

Seat, 

Hardened

4 FM Pressure Relief Spring FM Pressure 1 Steel 12L14 $0.01

Seat, Washed Relief Spring 

Seat, Washed

5 FM Pressure Relief Spring FM Pressure 1 Steel 12L14

Seat, Machined Relief Spring 

Seat, 

Machined1

6 FM Pressure Relief Spring FM Pressure 1 Steel 12L14

Seat, Stamped Relief Spring 

Seat, Stamped

7 FM Pressure Relief Spring FM Pressure 1 Steel 12L14

Seat, Material Relief Spring 

Seat, Material

2 FM Pressure Relief Clip FM Pressure 4 Commodity $0.01

Relief Clip Pricing

2 FM Check Valve FM Check 8 Commodity $0.12

Valve Pricing

2 FM Valve Actuation Piston FM Valve 8 $0.27

Actuation 

Piston

3 FM Valve Actuation Piston, FM Valve 1 Steel 12L14 $0.01

Cap Actuation 

Piston, Cap

4 FM Valve Actuation Piston, FM Valve 1 Steel 12L14 $0.01

Cap Blank Machined Actuation 

Piston, Cap 

Blank 

Machined

Design Profit®
Page 

4 of 13

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Level Symbol Name Number Qty Material Piece Cost

5 FM Valve Actuation Piston, FM Valve 1 Steel 12L14

Cap Blank Actuation 

Piston, Cap 

Blank

6 FM Valve Actuation Piston, FM Valve 1 Steel 12L14

Cap Blank Material Actuation 

Piston, Cap 

Blank Material

3 FM Valve Actuation Piston, FM Valve 1 Commodity $0.02

Clip Actuation Pricing

Piston, Clip

3 FM Valve Actuation Piston, FM Valve 1 Steel 12L14 $0.02

Long Pin Actuation 

Piston, Long 

Pin

4 FM Valve Actuation Piston, FM Valve 1 Steel 12L14 $0.02

Long Pin Washed Actuation 

Piston, Long 

Pin Washed

5 FM Valve Actuation Piston, FM Valve 1 Steel 12L14

Long Pin Ground Actuation 

Piston, Long 

Pin Ground

6 FM Valve Actuation Piston, FM Valve 1 Steel 12L14

Hardened Actuation 

Piston, 

Hardened

7 FM Valve Actuation Piston, FM Valve 1 Steel 12L14

Long Pin Blank Machined Actuation 

Piston, Long 

Pin Blank 

Machined

8 FM Valve Actuation Piston, FM Valve 1 Steel 12L14

Long Pin Blank Actuation 

Piston, Long 

Pin Blank

9 FM Valve Actuation Piston, FM Valve 1 Steel 12L14

Long Pin Blank Material Actuation 

Piston, Long 

Pin Blank 

Material
Design Profit®

Page 5 of 13

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Level Symbol Name Number Qty Material Piece Cost Weight

FM Valve Actuation Piston, FM Valve 1 Stamped Steel $0.01

Spring Guide Actuation 

Piston, Spring 

Guide

4 FM Valve Actuation Piston, FM Valve 1 Steel 12L14 $0.01

Spring Guide Stamped Actuation 

Piston, Spring 

Guide 

Stamped

5 FM Valve Actuation Piston, FM Valve 1 Steel 12L14

Spring Guide Material Actuation 

Piston, Spring 

Guide Material

3 FM Valve Actuation Piston, FM Valve 1 Commodity $0.01

Spring Actuation Pricing

Piston, Spring

3 FM Valve Actuation Piston, FM Valve 1 Steel 12L14 $0.11

Housing Actuation 

Piston, 

Housing

4 FM Valve Actuation Piston, FM Valve 1 Steel 12L14 $0.11

Ground Actuation 

Piston, 

Ground

5 FM Valve Actuation Piston, FM Valve 1 Steel 12L14

Housing Heat Treated Actuation 

Piston, 

Housing Heat 

Treated

6 FM Valve Actuation Piston, FM Valve 1 Steel 12L14

Housing Machined Actuation 

Piston, 

Housing 

Machined

7 FM Valve Actuation Piston, FM Valve 1 Steel 12L14

Housing Material Actuation 

Piston, Housing 

Material

3 FM Valve Actuation Piston, FM Valve 1 $0.01

Short Pin Actuation 

Piston, Short 

Pin

Design Profit®
Page 

6 of 13

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Level Symbol Name Number Qty Material Piece Cost

4 FM Valve Actuation Piston, FM Valve 1 Steel 12L14 $0.01

Short Pin Washed Actuation 

Piston, Short 

Pin Washed

5 FM Valve Actuation Piston, FM Valve 1 Steel 12L14

Short Pin Blank Machine Actuation 

Piston, Short 

Pin Blank 

Machine

6 FM Valve Actuation Piston, FM Valve 1 Steel 12L14

Short Pin Hardened Actuation 

Piston, Short 

Pin Hardened1

7 FM Valve Actuation Piston, FM Valve 1 Steel 12L14

Short Pin Blank Actuation 

Piston, Short 

Pin Blank

8 FM Valve Actuation Piston, FM Valve 1 Steel 12L14

Short Pin Material Actuation 

Piston, Short 

Pin Material

3 FM Valve Actuation Piston, FM Valve 1 Commodity $0.04

Yellow O-Ring Actuation Pricing

Piston, Yellow 

O-Ring

3 FM Valve Actuation Piston, FM Valve 1 Commodity $0.04

Black O-Ring Actuation Pricing

Piston, Black 

O-Ring

2 FM Oil Control Solenoid Asm FM Oil Control 4 $0.83

Solenoid Asm

3 FM Oil Control Solenoid FM Oil Control 1 $0.78

Solenoid1

4 FM Solenoid Plunger Assy FM Solenoid 1 $0.32

Plunger Assy

5 FM Solenoid Plunger FM Plunger 1 Steel Bar 1018

Housing Housing

6 FM Solenoid Plunger FM Solenoid 1 Steel Bar 1018

Housing, Washed Plunger 

Housing, 

Washed
Design Profit®

Page 7 of 13

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Level Symbol Name Number Qty Material Piece Cost

FM Solenoid Plunger FM Solenoid 1 Steel Bar 1018

Housing, Machined Plunger 

Housing, 

Machined

8 FM Solenoid Plunger Housing, FM Solenoid 1 Steel Bar 1018

Material Plunger 

Housing, 

Material

5 FM Solenoid Plunger Stop FM Plunger 1

Stop

6 FM Solenoid Plunger Stop, FM Solenoid 1

Hardened Plunger Stop, 

Hardened

7 FM Solenoid Plunger Stop, FM Solenoid 1 Steel 12L14

Machined Plunger Stop, 

Machined

8 FM Solenoid Plunger Stop, FM Solenoid 1

Headed Plunger Stop, 

Headed

9 FM Solenoid Plunger Stop, FM Solenoid 1 Steel 12L14

Material Plunger Stop, 

Material

5 FM Plunger Sub Assy FM Plunger 1

Sub Assy

6 FM Solenoid Plunger Frame FM Solenoid 1

Plunger Frame

7 FM Solenoid Plunger Frame, FM Solenoid 1 Stainless Steel 

Stamped Plunger -304

Frame, 

Stamped

8 FM Solenoid Plunger Frame, FM Solenoid 1 Stainless Steel 

Material Plunger Frame, -304

Material

6 FM Solenoid Plunger Frame FM Solenoid 1 Nylon 6/6

Piston Stop Plunger Frame 

Piston Stop

7 FM Solenoid Plunger Frame FM Solenoid 1 Nylon 6/6

Piston Stop, Material Plunger Frame 

Piston Stop, 

Material

6 FM Solenoid Plunger Piston FM Solenoid 1

Assy Plunger Piston 

Assy

Design Profit®
Page 

8 of 13

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Level Symbol Name Number Qty Material Piece Cost

FM Solenoid Plunger Piston FM Solenoid 1

Body Plunger Piston 

Body

8 FM Solenoid Plunger Piston FM Solenoid 1 Steel 12L14

Body, Hardened Plunger Piston 

Body, 

Hardened

9 FM Solenoid Plunger Piston FM Solenoid 1 Steel 12L14

Body, Machined Plunger Piston 

Body, 

Machined

# FM Solenoid Plunger Piston FM Solenoid 1 Steel 12L14

Body, Headed Plunger Piston 

Body, Headed

# FM Solenoid Plunger Piston FM Solenoid 1 Steel 12L14

Body, Material Plunger Piston 

Body, Material

7 FM Solenoid Plunger Piston FM Solenoid 1

Body Shaft Plunger Piston 

Body Shaft

8 FM Solenoid Plunger Piston FM Solenoid 1 Stainless Steel 

Body Shaft, Material Plunger Piston -304

Body Shaft, 

Material

6 FM Solenoid Plunger Piston FM Solenoid 1 Commodity 

Spring Plunger Piston Pricing

Spring

6 FM Solenoid Plunger Piston FM Solenoid 1

Body Assy Plunger Piston 

Body Assy

7 FM Solenoid Plunger Piston FM Solenoid 1

Body Assy, Body Plunger Piston 

Body Assy, 

Body

8 FM Solenoid Plunger Piston FM Solenoid 1

Body Assy, Body Hardene Plunger Piston 

Body Assy, 

Body Hardene

9 FM Solenoid Plunger Piston FM Solenoid 1

Body Assy, Body Machine Plunger Piston 

Body Assy, 

Body Machine

Design Profit®
Page 

9 of 13

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Level Symbol Name Number Qty Material

FM Solenoid Plunger Piston FM Solenoid 1 Steel 12L14

Body Assy, Body Materia Plunger Piston 

Body Assy, 

Body Materia

7 FM Solenoid Plunger Piston FM Solenoid 1 Steel 12L14

Body Assy, Insert Plunger Piston 

Body Assy, 

Insert

8 FM Solenoid Plunger Piston FM Solenoid 1 Steel 12L14

Body Assy, Insert Machi Plunger Piston 

Body Assy, 

Insert Machi

9 FM Solenoid Plunger Piston FM Solenoid 1 Steel 12L14

Body Assy, Insert Mater Plunger Piston 

Body Assy, 

Insert Mater

5 FM Solenoid Plunger Pin FM Solenoid 1

Assy Plunger Pin 

Assy

6 FM Solenoid Plunger Pin FM Plunger 1

Pin

7 FM Solenoid Plunger Pin, FM Solenoid 1 Steel 12L14

Hardened Plunger Pin, 

Hardened

8 FM Solenoid Plunger Pin, FM Solenoid 1 Steel 12L14

Machined Plunger Pin, 

Machined

9 FM Solenoid Plunger Pin, FM Solenoid 1 Steel 12L14

Headed Plunger Pin, 

Headed

# FM Solenoid Plunger Pin, FM Solenoid 1 Steel 12L14

Material Plunger Pin, 

Material

6 FM Solenoid Plunger Pin FM Plunger 1

Spacer Pin Spacer

7 FM Solenoid Plunger Pin FM Solenoid 1 Steel 12L14

Spacer, Hardened Plunger Pin 

Spacer, 

Hardened

8 FM Solenoid Plunger Pin FM Solenoid 1 Steel 12L14

Spacer, Machined Plunger Pin 

Spacer, 

Machined

Design Profit®
Page 10 of 13

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Level Symbol Name Number Qty Material Piece Cost

9 FM Solenoid Plunger Pin FM Solenoid 1 Steel 12L14

Spacer, Material Plunger Pin 

Spacer, 

Material

6 FM Solenoid Plunger Pin FM Plunger 1

Seal Pin Seal

7 FM Solenoid Plunger Pin Seal, FM Solenoid 1 Nylon 6 

Material Plunger Pin 

Seal, Material

5 FM Solenoid Plunger Spring, FM Plunger 1 Commodity 

Large Spring, Large Pricing

5 FM Solenoid Plunger Spring, FM Plunger 1 Commodity 

Small Spring, Small Pricing

5 FM Solenoid Plunger Nose FM Plunger 1 Steel - 1050

Piece Nose Piece

6 FM Solenoid Plunger Nose FM Solenoid 1 Steel - 1050

Piece, Stamped Plunger Nose 

Piece, 

Stamped

7 FM Solenoid Plunger Nose FM Solenoid 1 Steel - 1050

Piece, Material Plunger Nose 

Piece, Material

4 FM Solenoid Shell FM Solenoid 1 LC-Steel-1215, $0.09

Shell Tubing

5 FM Solenoid Shell Machined FM Solenoid 1 LC-Steel-1215, 

Shell Tubing

Machined

6 FM Solenoid Shell Material FM Solenoid 1 LC-Steel-1215, 

Shell Material Tubing

4 FM Electrical Assembly FM Electrical 1 $0.36

Assembly

5 FM Bobbin Assembly FM Bobbin 1

Assembly

6 FM Bobbin FM Bobbin 1 Commodity

Pricing

6 FM Bobbin Wire FM Bobbin Wire 1 Copper Wire 20 

AWG

6 FM Bobbin Terminals FM Bobbin 2

Terminals

5 FM Bobbin Spacer FM Bobbin 1

Spacer

Design Profit®
Page 11 of 13

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Level Symbol Name Number Qty Material Piece Cost

6 FM Bobbin Spacer, Peened FM Bobbin 1

Spacer, 

Peened

7 FM Bobbin Spacer, FM Bobbin 1

Machined Spacer, 

Machined

8 FM Bobbin Spacer, Material FM Bobbin 1 Steel - 1008

Spacer, 

Material

5 FM Electrical Assembly, Mold FM Electrical 1 PBTGF-30FR

Material Assembly, Mold (17)

Material

3 FM Label, Solenoid FM Label, 1 $0.05

Solenoid

2 FM Oil Temp Sensor FM Oil Temp 1 Commodity $2.49

Sensor Pricing

2 FM Primary Oil Feed O-Ring, FM Primary Oil 1 Commodity $0.04

Center Hsg. Feed O-Ring, Pricing

Center Hsg.

0 FM Solenoid Housing Bolt FM Solenoid 9 Commodity $0.06

Housing Bolt Pricing

0 FM Solenoid Cover Plate FM Solenoid 1 $1.71

Assy Cover Plate 

Assy

1 FM Solenoid Cover Base FM Solenoid 1 $1.36

Plate Cover Base 

Plate

2 FM Solenoid Cover Base FM Solenoid 1 $1.33

Plate, Washed Cover Base 

Plate, Washed

3 FM Solenoid Cover Base FM Solenoid 1 $1.33

Plate, Machined Cover Base 

Plate, 

Machined

4 FM Solenoid Cover Base FM Solenoid 1 Aluminum $1.33

Plate, Stamped Cover Base 

Plate, Stamped

5 FM Solenoid Cover Base FM Solenoid 1 Aluminum - 

Plate, Material Cover Base 30xx

Plate, Material

Design Profit®
Page 12 of 13

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Level Symbol Name Number Qty Material Piece Cost Weight

2 FM Solenoid Cover Base Plate FM Solenoid 1 Permatex - $0.03

Gasket Material Cover Base Ultra Copper, 

Plate Gasket 101BR

Material

1 FM Solenoid Cover Check FM Solenoid 1 Commodity $0.12

Valve Cover Check Pricing

Valve

1 FM Solenoid Cover Plate FM Solenoid 1 PMP Plastic $0.07

Gasket Cover Plate Metal Plastic

Gasket

2 FM Solenoid Cover Plate FM Solenoid 1 PMP Plastic $0.07

Gasket Material Cover Plate Metal Plastic

Gasket Material

1 FM Solenoid Cover Plate FM Solenoid 1 Galvinized $0.16

Cover Plate1 Steel - G60

2 FM Solenoid Cover Plate, FM Solenoid 1 Galvinized $0.16

Washed Cover Plate, Steel - G60

Washed

3 FM Solenoid Cover Plate FM Solenoid 1 Galvinized $0.16

Stamped Cover Plate Steel - G60

Stamped

4 FM Solenoid Cover Plate FM Solenoid Cover Plate FM Solenoid FM Solenoid 1 Galvinized Galvinized $0.16

Material Cover Plate Steel - G60

Material

0 FM Solenoid Cover Plate Bolt FM Solenoid # Commodity $0.03

Cover Plate Pricing

Bolt

Assembly Totals Report Totals

Analyzed Subs: # Piece Cost (Total): $31.12

Unanalyzed Subs: #

Weight (Total): 10.9784 lb

Parts: #

Fasteners:#

Parts+Unanaly # zed:

Design Profit®

Page 13 of 13
Copyright 2010 © Design Profit, Inc.
Piece Cost Weight (Total)

(Total)

0.0305 lb 0.0305 lb

0.0000 lb # 0.0000 lb

9.5582 lb # 9.5582 lb

9.5582 lb # 9.5582 lb

5.7050 lb # 5.7050 lb

5.7050 lb # 5.7050 lb

5.7050 lb # 5.7050 lb

$10.69 5.7050 lb # 5.7050 lb

$10.69 5.7050 lb # 5.7050 lb

$10.69 5.7050 lb # 5.7050 lb

$10.69 0.0000 lb # 0.0000 lb

0.0066 lb # 0.0264 lb

0.0000 lb # 0.0000 lb

Piece Cost Weight (Total)

(Total)

0.0000 lb # 0.0000 lb

0.0000 lb # 0.0000 lb

0.0000 lb # 0.0000 lb

0.0000 lb # 0.0000 lb

0.0110 lb # 0.0440 lb

0.0000 lb # 0.0000 lb

0.0000 lb # 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

0.0667 lb # 0.2668 lb

0.0000 lb # 0.0000 lb

0.0000 lb # 0.0000 lb

$0.12 0.0000 lb # 0.0000 lb

$0.12 0.0000 lb # 0.0000 lb

0.1090 lb # 0.4360 lb

0.1000 lb # 0.4000 lb

Weight Piece Cost Weight (Total)

(Total)

0.1000 lb 0.4000 lb

$0.07 0.1000 lb # 0.4000 lb

$0.07 0.1000 lb # 0.4000 lb

$0.07 0.0000 lb # 0.0000 lb

0.0085 lb # 0.0340 lb

0.0000 lb # 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

0.0005 lb # 0.0020 lb

0.0269 lb # 0.1076 lb

0.1368 lb # 0.5472 lb

0.0004 lb # 0.0016 lb

0.0139 lb # 0.0556 lb

0.0000 lb # 0.0000 lb

0.0000 lb # 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

Weight Piece Cost Weight (Total)

(Total)

$0.01 0.0000 lb # 0.0000 lb

0.0283 lb # 0.1132 lb

0.0133 lb # 0.0532 lb

0.0000 lb # 0.0000 lb

0.0000 lb # 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

0.0014 lb # 0.0056 lb

0.0066 lb # 0.0528 lb

0.1034 lb # 0.8272 lb

0.0098 lb # 0.0784 lb

0.0000 lb # 0.0000 lb

Weight Piece Cost Weight (Total)

(Total)

$0.01 0.0000 lb # 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

0.0001 lb # 0.0008 lb

0.0142 lb # 0.1136 lb

0.0000 lb # 0.0000 lb

$0.02 0.0000 lb # 0.0000 lb

$0.02 0.0000 lb # 0.0000 lb

$0.02 0.0000 lb # 0.0000 lb

$0.02 0.0000 lb # 0.0000 lb

# 0.0000 lb # 0.0000 lb

Weight Piece Cost Weight (Total)

(Total)

0.0003 lb 0.0024 lb

0.0000 lb # 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

0.0005 lb # 0.0040 lb

0.0676 lb # 0.5408 lb

0.0676 lb # 0.5408 lb

$0.11 0.0000 lb # 0.0000 lb

$0.11 0.0000 lb # 0.0000 lb

$0.11 0.0000 lb # 0.0000 lb

0.0100 lb # 0.0800 lb

Weight Piece Cost Weight (Total)

(Total)

0.0000 lb 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

0.0004 lb # 0.0032 lb

0.0005 lb # 0.0040 lb

0.3124 lb # 1.2496 lb

0.3124 lb # 1.2496 lb

0.1390 lb # 0.5560 lb

$0.15 0.0821 lb # 0.3284 lb

$0.15 0.0000 lb # 0.0000 lb

Weight Piece Cost Weight (Total)

(Total)

$0.15 0.0000 lb # 0.0000 lb

$0.15 0.0000 lb # 0.0000 lb

$0.01 0.0020 lb # 0.0080 lb

$0.01 0.0000 lb # 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

# 0.0000 lb # 0.0000 lb

$0.10 0.0477 lb # 0.1908 lb

$0.00 0.0034 lb # 0.0136 lb

$0.00 0.0000 lb # 0.0000 lb

$0.00 0.0000 lb # 0.0000 lb

$0.02 0.0005 lb # 0.0020 lb

$0.02 0.0000 lb # 0.0000 lb

$0.02 0.0128 lb # 0.0512 lb

Weight Piece Cost Weight (Total)

(Total)

$0.01 0.0103 lb # 0.0412 lb

$0.01 0.0000 lb # 0.0000 lb

# 0.0000 lb # 0.0000 lb

# 0.0000 lb # 0.0000 lb

# 0.0000 lb # 0.0000 l

$0.01 0.0025 lb # 0.0100 lb

$0.01 0.0000 lb # 0.0000 lb

$0.01 0.0005 lb # 0.0020 lb

$0.05 0.0012 lb # 0.0048 lb

$0.04 0.0000 lb # 0.0000 lb

$0.04 0.0000 lb # 0.0000 lb

# 0.0000 lb # 0.0000 lb

Piece Cost Weight Piece Cost Weight (T

(Total)

0.0000 lb 0.0000 lb

$0.01 0.0012 lb # 0.0048 lb

$0.01 0.0000 lb # 0.0000 lb

# 0.0000 lb # 0.0000 lb

$0.03 0.0037 lb # 0.0148 lb

$0.01 0.0030 lb # 0.0120 lb

$0.01 0.0000 lb # 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

# 0.0000 lb # 0.0000 lb

# 0.0000 lb # 0.0000 lb

$0.01 0.0006 lb # 0.0024 lb

$0.01 0.0000 lb # 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

Piece Cost Weight Piece Cost Weight (Tota

(Total)

# 0.0000 lb # 0.0000 lb

$0.01 0.0001 lb # 0.0004 lb

$0.01 0.0000 lb # 0.0000 lb

$0.01 0.0012 lb # 0.0048 lb

$0.01 0.0012 lb # 0.0048 lb

$0.01 0.0011 lb # 0.0044 lb

$0.01 0.0000 lb # 0.0000 lb

$0.01 0.0000 lb # 0.0000 lb

0.0788 lb # 0.3152 lb

$0.09 0.0000 lb # 0.0000 lb

$0.09 0.0000 lb # 0.0000 lb

0.0946 lb # 0.3784 lb

$0.28 0.0565 lb # 0.2260 lb

$0.10 0.0040 lb # 0.0160 lb

$0.12 0.0505 lb # 0.2020 lb

$0.03 0.0010 lb # 0.0080 lb

$0.03 0.0155 lb # 0.0620 lb

Weight Piece Cost Weight (Total)

(Total)

$0.03 0.0000 lb 0.0000 lb

$0.03 0.0000 lb # 0.0000 lb

$0.03 0.0000 lb # 0.0000 lb

$0.05 0.0226 lb # 0.0904 lb

0.0000 lb # 0.0000 lb

0.0611 lb # 0.0611 lb

0.0005 lb # 0.0005 lb

0.0505 lb # 0.4545 lb

0.8110 lb # 0.8110 lb

0.0022 lb # 0.0022 lb

0.0000 lb # 0.0000 lb

0.0000 lb # 0.0000 lb

0.0000 lb # 0.0000 lb

$1.33 0.0000 lb # 0.0000 lb

Piece Cost Weight (Total)

(Total)

0.0355 oz # 0.0355 oz

0.0060 lb # 0.0060 lb

0.0500 lb # 0.0500 lb

0.0000 lb # 0.0000 lb

0.3100 lb # 0.3100 lb

0.0000 lb # 0.0000 lb

0.0000 lb # 0.0000 lb

0.0000 lb # 0.0000 lb

0.0069 lb # 0.1242 lb

Preassembled Totals

Analyzed Subs: 0

Unanalyzed Subs: 0

Parts: 0

Fasteners:0

Parts+Unanalyzed: 0

Assembly Report

FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$35.51 Tool FM Multi Air First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

System

$24.60 P.-P. Part FM Multi Air FM Solenoid Housing Gasket FM Solenoid 8.0000 sec 8.0000 sec - $0.08 1

System Housing Gasket

$24.60 Tool FM Solenoid Stamping Press 60-200 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing Gasket

$24.60 Part FM Solenoid FM Solenoid Housing Gasket FM Solenoid 0.0000 sec 1.7000 sec $0.09 $0.01 1

Housing Gasket Material Housing Gasket 

Material

- - - Blank weight .126 lbs - - - - - -

- - - Press Size 200 Ton Progressive - - - - - -

- - - Part Size after stamping (352 L - - - - - -

by 51 W by .5 H)mm

- - - Install Solenoid Housing - - - - - -

Assembly

$50.00 Subassembly FM Multi Air FM Solenoid Housing Assy, FM Solenoid 7.0000 sec 7.0000 sec - $0.07 1

System Tested Housing Assy, 

Tested

$50.00 Tool FM Solenoid First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing Assy, 

Tested

$35.51 Subassembly FM Solenoid FM Solenoid Housing Assy FM Solenoid 4.0000 sec 4.0000 sec - $0.06 1

Housing Assy, Housing Assy

Tested

$35.51 Tool FM Solenoid First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing Assy

$25.00 P.-P. Part FM Solenoid FM Solenoid Housing, Tested FM Solenoid 4.0000 sec 4.0000 sec - $0.04 1

Housing Assy Housing, Tested

$25.00 Tool FM Solenoid First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Tested

$35.51 P.-P. Part FM Solenoid FM Solenoid Housing, Numbered FM Solenoid 4.0000 sec 4.0000 sec - $0.03 1

Housing, Tested Housing, 

Numbered

$35.51 Tool FM Solenoid First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, 

Numbered

Design Profit ®
Page 

1 of#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$49.29 P.-P. Part FM Solenoid FM Solenoid Housing, Washed FM Solenoid 4.0000 sec 4.0000 sec - $0.04 1

Housing, Housing, Washed

Numbered

$49.29 Tool FM Solenoid Washer Turbo Tunnel 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Washed

$47.77 P.-P. Part FM Solenoid FM Solenoid Housing, Machined FM Solenoid 4.0000 sec 4.0000 sec - $0.05 1

Housing, Washed Housing, 

Machined

$47.77 Tool FM Solenoid EC-400-ML Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Machine

Machined

$42.18 P.-P. Part FM Solenoid FM Solenoid Housing, Trimmed FM Solenoid 4.0000 sec 4.0000 sec - $0.05 1

Housing, Housing, Trimmed

Machined

$42.18 Tool FM Solenoid Trim Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Trimmed

###### P.-P. Part FM Solenoid FM Solenoid Housing, Forged FM Solenoid 4.0000 sec 8.5700 sec - $0.10 1

Housing, Trimmed Housing, Forged

###### Tool FM Solenoid Forging Press 500 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, Forged

- - - Forging Line Includes Cut Off, - - - - - -

Press

- - - Induction Heater and Robotic part - - - - - -

handling

###### Part FM Solenoid FM Solenoid Housing, Material FM Solenoid 0.0000 sec 0.0000 sec $8.18 $0.00 1

Housing, Forged Housing, Material

- - - Raw Material Req 7.129 lbs - - - - - -

- - - Box Size 352.5mm L x 95.25mm - - - - - -

W x 67mm H

###### Material Mod. FM Solenoid Forge 500T 0.8500 sec 0.8500 sec $0.00 $0.03 1

Housing, Forged

###### Operation FM Solenoid Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.10 1

Housing, Forged

###### Material Mod. FM Solenoid Forge 500T 0.8500 sec 0.8500 sec $0.00 $0.03 1

Housing, Forged

###### Operation FM Solenoid Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.10 1

Housing, Forged

###### Material Mod. FM Solenoid Forge 500T 0.8500 sec 0.8500 sec $0.00 $0.03 1

Housing, Forged

$47.77 Operation FM Solenoid Bar Feeder Load & Clamp 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, 

Machined

Design Profit ®
Page 

2 of#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$47.77 Operation FM Solenoid Pallet to workspace/tool to pallet 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

- - - Machine From Top Direction - - - - - -

- - - Machine (8) Valve Actuation - - - - - -

Holes

$47.77 Material Mod. FM Solenoid Drill Hole 30 - 60mm 2.0000 sec 2.0000 sec $0.00 $0.03 8

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 7

Housing, 

Machined

- - - Bore 1st Valve Hole Diameter - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 8

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 7

Housing, 

Machined

- - - Bore 2nd Valve Hole Diameter - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 8

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 7

Housing, 

Machined

- - - Bore 3rd Valve Hole Diameter - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 8

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 7

Housing, 

Machined

Design Profit ®
Page 

3 of#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Bore 4th Valve Hole Diameter & - - - - - -

Chamfer

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Bore Hole & Chamfer 2.0000 sec 2.0000 sec $0.00 $0.03 8

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 7

Housing, 

Machined

- - - Cut Valve Threads - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Tap Hole 0.5000 sec 0.5000 sec $0.00 $0.01 8

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 7

Housing, 

Machined

- - - Bore Off-Center Hole Bore Off-Center Hole - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 8

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 7

Housing, 

Machined

- - - Machine (4) Pressure Relief - - - - - -

Holes

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

- - - Bore 1st Pressure Relief Hole - - - - - -

Diameter

$47.77 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

Design Profit ®
Page 

4 of#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

- - - Drill Through Hole - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Drill Hole 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

- - - Bore 2nd Pressure Relief Hole - - - - - -

Diameter

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$47.77 Operation Operation FM Solenoid FM Solenoid CDI 1.0000 sec 1.0000 sec 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

- - - Bore Off-Center Diameter - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

- - - Bore 3rd Pressure Relief Hole - - - - - -

Dia & Chamfer Hole

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Bore Hole & Chamfer 2.0000 sec 2.0000 sec $0.00 $0.03 4

Housing, 

Machined

Design Profit ®
Page 

5 of#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

- - - Machine Gasket Surface - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Mill Gasket Surface 10.0000 sec 10.0000 sec $0.00 $0.13 1

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

- - - Mill Mounting Hole Surfaces - - - - - -

$47.77 Material Mod. FM Solenoid Milled face 1.0000 sec 1.0000 sec $0.00 $0.01 5

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

- - - Machine Top of Rocker Pin Nubs - - - - - -

$47.77 Material Mod. Material Mod. FM Solenoid FM Solenoid Mill Flat Med Mill Flat Med 4.0000 sec 4.0000 sec 4.0000 sec 4.0000 sec $0.00 $0.05 1

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

- - - Machine Under Cut Clearance for - - - - - -

Spark Plug Tube 

$47.77 Material Mod. FM Solenoid Mill Face 2.0000 sec 2.0000 sec $0.00 $0.03 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

- - - Bore Clearance for Spark Plug - - - - - -

Tube

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

Design Profit ®
Page 

6 of#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$47.77 Material Mod. FM Solenoid Bore Hole 30-60mm 2.0000 sec 2.0000 sec $0.00 $0.03 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

- - - Machine Face of Rocker Pin - - - - - -

Nubs

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Special Cutter 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

- - - Sot Face O-Ring Surface - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Spot Face 0.5000 sec 0.5000 sec $0.00 $0.01 1

Housing, 

Machined

- - - Drill Holes Drill Holes - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 9

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 8

Housing, 

Machined

- - - C'Bore (3) Mounting Holes - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Counter Bore Hole Small 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 2

Housing, 

Machined

- - - Machine One End Surface - - - - - -

Design Profit ®
Page 

7 of#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Mill Face 2.0000 sec 2.0000 sec $0.00 $0.03 2

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

- - - Machine Other End Surface - - - - - -

$47.77 Operation FM Solenoid Move 2.0000 sec 2.0000 sec $0.00 $0.03 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Mill Face 2.0000 sec 2.0000 sec $0.00 $0.03 2

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Tool to home/pallet to operator 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Remove Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Housing, 

Machined

$47.77 Operation FM Solenoid Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, 

Machined

- - - Machining From Rocker Arm - - - - - -

Direction

- - - Machine Rocker Piston Holes & - - - - - -

Surface

$47.77 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, 

Machined

$47.77 Operation FM Solenoid Pallet to workspace/tool to pallet 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

Design Profit ®
Page 

8 of#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$47.77 Operation FM Solenoid Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, 

Machined

- - - Bore 1st Rocker Piston Hole - - - - - -

Diameter

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

- - - Bore 2nd Rocker Piston Hole - - - - - -

Diameter

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

- - - Bore 3rd Rocker Piston Hole - - - - - -

Diameter

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

- - - Bore 4th Rocker Piston Hole - - - - - -

Diameter

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

Design Profit ®
Page 

9 of#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$47.77 Material Mod. FM Solenoid Bore Hole & Chamfer 2.0000 sec 2.0000 sec $0.00 $0.03 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

- - - Cut Piston Threads - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Tap Hole 0.5000 sec 0.5000 sec $0.00 $0.01 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

- - - Mill Clearance Slots - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Mill Slot 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

- - - Drill Rocker Pin Holes - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Drill Hole 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

- - - Bore Rocker Pin Holes - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

Design Profit ®
Page 10 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$47.77 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

$47.77 Operation FM Solenoid Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Tool to home/pallet to operator 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Remove Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Housing, 

Machined

$47.77 Operation FM Solenoid Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, 

Machined

- - - Machining From Solenoid Holes - - - - - -

Direction

$47.77 Operation FM Solenoid Pallet to workspace/tool to pallet 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, 

Machined

$47.77 Operation FM Solenoid Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, 

Machined

- - - Mill Shallow Slots - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Mill Slot 1.0000 sec 1.0000 sec $0.00 $0.01 2

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

- - - Mahine Bottom Surface Undercut - - - - - -

Design Profit ®
Page 11 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Mill Flat Med 4.0000 sec 4.0000 sec $0.00 $0.05 1

Housing, 

Machined

- - - Machine Solenoid Holes - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Bore Hole 30-60mm 2.0000 sec 2.0000 sec $0.00 $0.03 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Spot Face Small 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Bore Hole & Chamfer 2.0000 sec 2.0000 sec $0.00 $0.03 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

Design Profit ®
Page 12 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Drill Oil Holes to Valves - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Drill Oil Hole 2.0000 sec 2.0000 sec $0.00 $0.03 8

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 7

Housing, 

Machined

- - - Drill Oil Hole to Piston - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Drill Oil Supply Hole 2.0000 sec 2.0000 sec $0.00 $0.03 1

Housing, 

Machined

- - - Machine Oil Temp Sensor Hole - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. Material Mod. FM Solenoid FM Solenoid Drill Hole 30 - 60mm Drill Hole 30 - 60mm 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec $0.00 $0.03 1

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Bore Hole 30-60mm 2.0000 sec 2.0000 sec $0.00 $0.03 1

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

Design Profit ®
Page 13 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Tap Hole 4.0000 sec 4.0000 sec $0.00 $0.05 1

Housing, 

Machined

- - - Machine (2) Spot Holes - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Mill Face 2.0000 sec 2.0000 sec $0.00 $0.03 2

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 2

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Tool to home/pallet to operator 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Remove Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Housing, 

Machined

$47.77 Operation FM Solenoid Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, 

Machined

- - - Gun Drilling From End - - - - - -

$47.77 Operation FM Solenoid Pallet to workspace/tool to pallet 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

Design Profit ®
Page 14 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$47.77 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, 

Machined

$47.77 Operation FM Solenoid Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Mill Face 2.0000 sec 2.0000 sec $0.00 $0.03 1

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Gun Drill Oil Holes - 13.25" 5.0000 sec 5.0000 sec $0.00 $0.07 2

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation Operation FM Solenoid FM Solenoid Unclamp Part Unclamp Part 1.0000 sec 1.0000 sec 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Tool to home/pallet to operator 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Remove Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Housing, 

Machined

$47.77 Operation FM Solenoid Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, 

Machined

- - - Gun Drilling From Opposite End - - - - - -

$47.77 Operation FM Solenoid Pallet to workspace/tool to pallet 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, 

Machined

$47.77 Operation FM Solenoid Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, 

Machined

Design Profit ®
Page 15 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Mill Face 2.0000 sec 2.0000 sec $0.00 $0.03 1

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Gun Drill Oil Holes - 13.25" 5.0000 sec 5.0000 sec $0.00 $0.07 2

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Tool to home/pallet to operator 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation Operation FM Solenoid FM Solenoid Remove Part Remove Part 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec $0.00 $0.03 1

Housing, 

Machined

$47.77 Operation FM Solenoid Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, 

Machined

- - - Machining From Bottom Direction - - - - - -

$47.77 Operation FM Solenoid Pallet to workspace/tool to pallet 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, 

Machined

$47.77 Operation FM Solenoid Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, 

Machined

- - - Machine Bottom Surface - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

Design Profit ®
Page 16 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$47.77 Material Mod. FM Solenoid Mill Flat large 8.0000 sec 8.0000 sec $0.00 $0.11 1

Housing, 

Machined

- - - Machine Small Slot - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Mill Slot 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

- - - Drill, C'bore & Tap (4) Holes - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Drill Hole 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Counter Bore Hole Small 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Tap Hole 2.0000 sec 2.0000 sec $0.00 $0.03 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

- - - C'Bore (3) Holes - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

Design Profit ®
Page 17 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$47.77 Material Mod. FM Solenoid Counter Bore Hole Small 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 2

Housing, 

Machined

- - - Spot Face (6) Holes - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Spot Face 0.5000 sec 0.5000 sec $0.00 $0.01 6

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 5

Housing, 

Machined

- - - Drill & Ream (2) Dowel Holes - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Drill Hole 1.0000 sec 1.0000 sec $0.00 $0.01 2

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Ream Hole 1.0000 sec 1.0000 sec $0.00 $0.01 2

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

- - - Drill & Tap (18) Cover Holes - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 18

Housing, 

Machined

Design Profit ®
Page 18 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 17

Housing, 

Machined

- - - Machine (4) Oil Check Valve - - - - - -

Holes

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Counter Bore Hole Small 1.0000 sec 1.0000 sec $0.00 $0.01 4

Housing, 

Machined

$47.77 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 3

Housing, 

Machined

- - - Machine Oil Supply Hole - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Drill Hole 30 - 60mm 2.0000 sec 2.0000 sec $0.00 $0.03 1

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Bore Hole 30-60mm 2.0000 sec 2.0000 sec $0.00 $0.03 1

Housing, 

Machined

- - - Machine Filter Hole - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

Design Profit ®
Page 19 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$47.77 Material Mod. FM Solenoid Drill Hole 30 - 60mm 2.0000 sec 2.0000 sec $0.00 $0.03 1

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Mill Slot 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Spot Face 0.5000 sec 0.5000 sec $0.00 $0.01 1

Housing, 

Machined

- - - Drill Holes to Relief Valves - - - - - -

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Drill Hole 30 - 60mm 2.0000 sec 2.0000 sec $0.00 $0.03 4

Housing, 

Machined

- - - Machine Angled Cross Hole - - - - - -

(Plugged)

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Milled face 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Drill Hole 30 - 60mm 2.0000 sec 2.0000 sec $0.00 $0.03 1

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

$47.77 Material Mod. FM Solenoid Counter Bore Hole Small 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined
Design Profit

®

Page 20 of#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$47.77 Operation FM Solenoid Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Machined

$47.77 Operation FM Solenoid Remove Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Housing, 

Machined

$47.77 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Housing, 

Machined

$47.77 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, 

Machined

- - - In-Line Washer - - - - - -

$49.29 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Housing, Washed

$49.29 Operation FM Solenoid Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.07 1

Housing, Washed

$49.29 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 1

Housing, Washed

- - - Laser Etch Supplier Logo and - - - - - -

Part #

$35.51 Tool FM Solenoid FM Solenoid Laser Symbolizer Laser Symbolizer 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing, 

Numbered

$35.51 Material Mod. FM Solenoid Laser Etch 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Numbered

$35.51 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Numbered

- - - Laser Etch Part # on End of - - - - - -

Housing

$35.51 Material Mod. FM Solenoid Laser Etch 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing, 

Numbered

- - - Stamp "M" on End of Housing - - - - - -

$35.51 Tool FM Solenoid Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing, 

Numbered

$35.51 Material Mod. FM Solenoid Punch ID Character 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing, 

Numbered

Design Profit ®
Page 21 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Air Test - - - - - -

- - - Load/Unload Included - - - - - -

- - - Etch or Print Labeling - - - - - -

$25.00 Operation FM Solenoid Pressure Hold Test 12.0000 sec 12.0000 sec $0.00 $0.08 1

Housing, Tested

$35.51 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

$35.51 Operation FM Solenoid Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

- - - Install Oil Return Check Valve - - - - - -

$0.00 Subassembly FM Solenoid FM Oil Return Check Valve FM Oil Return 3.0000 sec 3.0000 sec $0.10 $0.03 4

Housing Assy Check Valve

$35.51 Tool FM Solenoid Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing Assy

$35.51 Fastening FM Solenoid Press to Depth 3.0000 sec 3.0000 sec $0.00 $0.03 4

Housing Assy

$35.51 Tool FM Solenoid Stake Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing Assy

$35.51 Fastening FM Solenoid Stake in Place 3.0000 sec 3.0000 sec $0.00 $0.03 4

Housing Assy

- - - Install (1) Check Valve - - - - - -

$35.51 Part FM Solenoid FM Solenoid Check Valve FM Solenoid 5.0000 sec 5.0000 sec $0.12 $0.05 1

Housing Assy Check Valve

$35.51 Tool FM Solenoid Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing Assy

$35.51 Fastening FM Solenoid Press to Depth 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

$35.51 Tool FM Solenoid Stake Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing Assy

$35.51 Fastening FM Solenoid Stake in Place 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

$35.51 Operation FM Solenoid Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing Assy

$35.51 Operation FM Solenoid Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

- - - Install (2) Ball Stops - - - - - -

$35.51 Operation FM Solenoid Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

$35.51 Part FM Solenoid FM Solenoid Housing Ball Stop FM Solenoid 3.0000 sec 3.0000 sec $0.04 $0.03 2

Housing Assy Housing Ball Stop

Design Profit ®
Page 22 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$35.51 Tool FM Solenoid Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing Assy

$35.51 Fastening FM Solenoid Press to Depth 3.0000 sec 3.0000 sec $0.00 $0.03 2

Housing Assy

$35.51 Tool FM Solenoid Stake Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing Assy

$35.51 Fastening FM Solenoid Stake in Place 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

$35.51 Operation FM Solenoid Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing Assy

$35.51 Operation FM Solenoid Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

- - - Install One Ball and Cup Stop - - - - - -

$35.51 Operation FM Solenoid Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

$35.51 Part FM Solenoid FM Solenoid Housing Ball Stop FM Solenoid 3.0000 sec 3.0000 sec $0.04 $0.03 1

Housing Assy Housing Ball Stop

$35.51 Part FM Solenoid FM Solenoid Housing Cup Stop FM Solenoid 3.0000 sec 3.0000 sec $0.02 $0.03 1

Housing Assy Housing Cup Stop

$35.51 Fastening FM Solenoid Press to Depth 3.0000 sec 3.0000 sec $0.00 $0.03 2

Housing Assy

$35.51 Tool FM Solenoid FM Solenoid Stake Tool Stake Tool 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing Assy

$35.51 Fastening FM Solenoid Stake in Place 3.0000 sec 3.0000 sec $0.00 $0.03 2

Housing Assy

$35.51 Operation FM Solenoid Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing Assy

$35.51 Operation FM Solenoid Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

- - - Install Ball Stop on Angle - - - - - -

$35.51 Operation FM Solenoid Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

$35.51 Part FM Solenoid FM Solenoid Housing Ball Stop FM Solenoid 3.0000 sec 3.0000 sec $0.04 $0.03 1

Housing Assy Housing Ball Stop

$35.51 Tool FM Solenoid Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing Assy

$35.51 Fastening FM Solenoid Press to Depth 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

$35.51 Tool FM Solenoid Stake Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing Assy

Design Profit ®
Page 23 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$35.51 Fastening FM Solenoid Stake in Place 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

$35.51 Operation FM Solenoid Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing Assy

$35.51 Operation FM Solenoid Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

- - - Install Rocker Pins - - - - - -

$35.51 Operation FM Solenoid Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$55.17 P.-P. Part FM Solenoid FM Rocker Pin FM Rocker Pin 3.0000 sec 3.0000 sec - $0.03 4

Housing Assy

$55.17 Tool FM Rocker Pin Plating Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 4

$46.52 P.-P. Part FM Rocker Pin FM Rocker Pin Heat Treated FM Rocker Pin 3.0000 sec 3.0000 sec - $0.05 4

Heat Treated

$46.52 Tool FM Rocker Pin First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 4

Heat Treated

$10.75 P.-P. Part FM Rocker Pin FM Rocker Pin Washed FM Rocker Pin 3.0000 sec 3.0000 sec - $0.04 4

Heat Treated Washed

$10.75 Tool FM Rocker Pin Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 4

Washed DRY

$20.90 P.-P. Part FM Rocker Pin FM Rocker Pin Machined FM Rocker Pin 3.0000 sec 3.0000 sec - $0.01 4

Washed Machined1

Design Profit ®

Page 24 of #

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$20.90 Tool FM Rocker Pin Grinding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 4

Machined

###### P.-P. Part FM Rocker Pin FM Rocker Pin Blank FM Rocker Pin 3.0000 sec 3.0000 sec - $0.02 4

Machined Blank

###### Tool FM Rocker Pin Forging Press 500 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 4

Blank

###### Part FM Rocker Pin FM Rocker Pin Material FM Rocker Pin 0.0000 sec 0.0000 sec $0.01 $0.00 4

Blank Material

- - - Raw Material Req .02 lbs Actual - - - - - -

+ %

- - - Box size of finished part 8.6Dmm - - - - - -

x 22Lmm

- - - 2 hits based on rough - near net - - - - - -

shape

###### Material Mod. FM Rocker Pin Forge 500T 0.8500 sec 0.8500 sec $0.00 $0.03 4

Blank

- - - 2nd hit required - - - - - -

###### Operation FM Rocker Pin Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.10 4

Blank

###### Material Mod. FM Rocker Pin Forge 500T 0.8500 sec 0.8500 sec $0.00 $0.03 4

Blank

###### Operation Operation FM Rocker Pin FM Rocker Pin Unload Part Unload Part 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec $0.00 $0.06 4

Blank

$20.90 Operation FM Rocker Pin Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 4

Machined

$20.90 Operation FM Rocker Pin Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.02 4

Machined

$20.90 Material Mod. FM Rocker Pin Grind to Length 1.0000 sec 1.0000 sec $0.00 $0.01 4

Machined

$20.90 Operation FM Rocker Pin Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 4

Machined

$20.90 Operation FM Rocker Pin Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 4

Machined

- - - Batch Type Washer - - - - - -

- - - 5-10 min cycle time - - - - - -

- - - Basket Size 15.75x18.50x25.50 - - - - - -

inches x 2

$10.75 Operation FM Rocker Pin Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 4

Washed

$10.75 Operation FM Rocker Pin Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 4

Washed

Design Profit ®
Page 25 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$10.75 Operation FM Rocker Pin Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 4

Washed

$46.52 Operation FM Rocker Pin Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 4

Heat Treated

$46.52 Material Mod. FM Rocker Pin Induction Harden 2.0000 sec 2.0000 sec $0.00 $0.03 4

Heat Treated

$46.52 Operation FM Rocker Pin Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Heat Treated

$55.17 Operation FM Rocker Pin Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 4

$55.17 Operation FM Rocker Pin Electroplate Process 0.3026 sec 1.8156 sec $0.00 $0.03 4

$55.17 Operation FM Rocker Pin Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

$35.51 Tool FM Solenoid Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing Assy

$35.51 Fastening FM Solenoid Press to Depth 3.0000 sec 3.0000 sec $0.00 $0.03 4

Housing Assy

- - - Install Rocker Arm System - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

$55.17 P.-P. Part FM Solenoid FM Rocker Piston Bore FM Rocker Piston 7.0000 sec 7.0000 sec - $0.07 4

Housing Assy Bore

$55.17 Tool FM Rocker Piston Plating Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 4

Bore

$46.52 P.-P. Part FM Rocker Piston FM Rocker Piston Bore, FM Rocker Piston 3.0000 sec 3.0000 sec - $0.05 4

Bore Hardened Bore, Hardened

$46.52 Tool FM Rocker Piston First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 4

Bore, Hardened

$10.75 P.-P. Part FM Rocker Piston FM Rocker Piston Bore, Washed FM Rocker Piston 3.0000 sec 3.0000 sec - $0.04 4

Bore, Hardened Bore, Washed

$10.75 Tool FM Rocker Piston Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 4

Bore, Washed DRY

$20.90 P.-P. Part FM Rocker Piston FM Rocker Piston Bore, FM Rocker Piston 3.0000 sec 3.0000 sec - $0.01 4

Bore, Washed Machined Bore, Machined

$20.90 Tool FM Rocker Piston CNC Turning 2 Axis SL-10, 1.75" 0.0000 sec 0.0000 sec $0.00 $0.00 4

Bore, Machined bar

- - - Includes Bar Feeder - - - - - -

$20.90 Part FM Rocker Piston FM Rocker Piston Bore, Material FM Rocker Piston 0.0000 sec 0.0000 sec $0.12 $0.00 4

Bore, Machined Bore, Material

Design Profit ®

Page 26 of #
Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Bar stock weight .20 lbs. - - - - - -

- - - Box size of finished part - - - - - -

25.17Dmm x 23.3Lmm

- - - ID Operations - - - - - -

$20.90 Operation FM Rocker Piston Bar Feeder Load & Clamp 3.0000 sec 3.0000 sec $0.00 $0.02 4

Bore, Machined

$20.90 Operation FM Rocker Piston Drill Hole 2.0000 sec 2.0000 sec $0.00 $0.01 4

Bore, Machined

$20.90 Operation FM Rocker Piston Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Bore, Machined

$20.90 Material Mod. FM Rocker Piston Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Bore, Machined

$20.90 Operation FM Rocker Piston Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Bore, Machined

$20.90 Operation FM Rocker Piston Ream Hole 1.0000 sec 1.0000 sec $0.00 $0.01 4

Bore, Machined

$20.90 Operation FM Rocker Piston Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Bore, Machined

$20.90 Material Mod. FM Rocker Piston Turn ID Lead-In 1.0000 sec 1.0000 sec $0.00 $0.01 4

Bore, Machined

- - - Outside Operations - - - - - -

$20.90 Operation Operation FM Rocker Piston FM Rocker Piston Auto Tool Change Auto Tool Change 5.0000 sec 5.0000 sec 5.0000 sec 5.0000 sec $0.00 $0.03 4

Bore, Machined

$20.90 Material Mod. FM Rocker Piston Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Bore, Machined

$20.90 Operation FM Rocker Piston CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Bore, Machined

$20.90 Material Mod. FM Rocker Piston Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Bore, Machined

$20.90 Operation FM Rocker Piston Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Bore, Machined

$20.90 Material Mod. FM Rocker Piston Turn Threads 2.0000 sec 2.0000 sec $0.00 $0.01 4

Bore, Machined

$20.90 Operation FM Rocker Piston Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Bore, Machined

$20.90 Material Mod. FM Rocker Piston Cut to Length 1.0000 sec 1.0000 sec $0.00 $0.01 4

Bore, Machined

$20.90 Operation FM Rocker Piston Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 4

Bore, Machined

$20.90 Operation FM Rocker Piston Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.02 4

Bore, Machined

Design Profit ®
Page 27 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$20.90 Operation FM Rocker Piston Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.02 4

Bore, Machined

$20.90 Material Mod. FM Rocker Piston Milled face 1.0000 sec 1.0000 sec $0.00 $0.01 24

Bore, Machined

$20.90 Operation FM Rocker Piston CDI 1.0000 sec 1.0000 sec $0.00 $0.01 20

Bore, Machined

$20.90 Operation FM Rocker Piston Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Bore, Machined

$20.90 Material Mod. FM Rocker Piston Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 4

Bore, Machined

$20.90 Operation FM Rocker Piston Auto Eject Part 0.5000 sec 0.5000 sec $0.00 $0.00 4

Bore, Machined

$20.90 Operation FM Rocker Piston Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Bore, Machined

- - - Batch Type Washer - - - - - -

- - - 5-10 min cycle time - - - - - -

- - - Basket Size 15.75x18.50x25.50 - - - - - -

inches x 2

$10.75 Operation FM Rocker Piston Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 4

Bore, Washed

$10.75 Operation FM Rocker Piston Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 4

Bore, Washed

$10.75 Operation FM Rocker Piston Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 4

Bore, Washed

$46.52 Operation FM Rocker Piston Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 4

Bore, Hardened

$46.52 Material Mod. FM Rocker Piston Induction Harden 2.0000 sec 2.0000 sec $0.00 $0.03 4

Bore, Hardened

$46.52 Operation FM Rocker Piston Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Bore, Hardened

$55.17 Operation FM Rocker Piston Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 4

Bore

$55.17 Operation FM Rocker Piston Electroplate Process 0.7565 sec 1.8156 sec $0.00 $0.03 4

Bore

$55.17 Operation FM Rocker Piston Remove Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Bore

$35.51 Tool FM Solenoid Power Tool 4.0000 sec 4.0000 sec $0.00 $0.04 1

Housing Assy

$35.51 Fastening FM Solenoid Power Screw 4.0000 sec 4.0000 sec $0.00 $0.04 4

Housing Assy

- - - Space for Printing - - - - - -

Design Profit ®
Page 28 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$83.31 Subassembly FM Solenoid FM Rocker Piston FM Rocker Piston 4.0000 sec 4.0000 sec - $0.04 4

Housing Assy

$83.31 Tool FM Rocker Piston First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 4

Design Profit ®

Page 29 of #

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$46.52 P.-P. Part FM Rocker Piston FM Rocker Piston, Shaft FM Rocker Piston, 3.0000 sec 3.0000 sec - $0.07 4

Shaft

$46.52 Tool FM Rocker Piston, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 4

Shaft

$10.75 P.-P. Part FM Rocker Piston, FM Rocker Piston, Shaft Washed FM Rocker Piston, 3.0000 sec 3.0000 sec - $0.04 4

Shaft Shaft Washed

$10.75 Tool FM Rocker Piston, Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 4

Shaft Washed DRY

$21.43 P.-P. Part FM Rocker Piston, FM Rocker Piston, Shaft FM Rocker Piston, 3.0000 sec 3.0000 sec - $0.01 4

Shaft Washed Machined Shaft Machined

$21.43 Tool FM Rocker Piston, CNC Turning 2 Axis SL-10, Odd 0.0000 sec 0.0000 sec $0.00 $0.00 4

Shaft Machined Form

###### P.-P. Part FM Rocker Piston, FM Rocker Piston, Shaft Blank FM Rocker Piston, 3.0000 sec 3.0000 sec - $0.02 4

Shaft Machined Shaft Blank

###### Tool FM Rocker Piston, Forging Press 500 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 4

Shaft Blank

###### Part FM Rocker Piston, FM Rocker Piston, Shaft Blank FM Rocker Piston, 0.0000 sec 0.0000 sec $0.07 $0.00 4

Shaft Blank Material Shaft Blank 

Material

- - - Raw Material Req 0.1 lbs Actual - - - - - -

+ %

- - - Box Size 14.1mm D x 35mm L Box Size 14.1mm D x 35mm L - - - - - -

- - - 2 hits based on rough - near net - - - - - -

shape

###### Material Mod. FM Rocker Piston, Forge 500T 0.8500 sec 0.8500 sec $0.00 $0.03 4

Shaft Blank

- - - If 2nd hit required - - - - - -

###### Operation FM Rocker Piston, Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.10 4

Shaft Blank

###### Material Mod. FM Rocker Piston, Forge 500T 0.8500 sec 0.8500 sec $0.00 $0.03 4

Shaft Blank

###### Operation FM Rocker Piston, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.06 4

Shaft Blank

$21.43 Operation FM Rocker Piston, Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 4

Shaft Machined

$21.43 Operation FM Rocker Piston, Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.02 4

Shaft Machined

- - - Turn Small Diameter - - - - - -

$21.43 Material Mod. FM Rocker Piston, Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Shaft Machined

- - - Cut Grooves - - - - - -

Design Profit ®
Page 30 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$21.43 Operation FM Rocker Piston, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Shaft Machined

$21.43 Material Mod. FM Rocker Piston, Cut Small Groove 0.5000 sec 0.5000 sec $0.00 $0.00 4

Shaft Machined

$21.43 Operation FM Rocker Piston, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Shaft Machined

$21.43 Material Mod. FM Rocker Piston, Cut Small Groove 0.5000 sec 0.5000 sec $0.00 $0.00 4

Shaft Machined

$21.43 Operation FM Rocker Piston, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Shaft Machined

$21.43 Material Mod. FM Rocker Piston, Cut Small Groove 0.5000 sec 0.5000 sec $0.00 $0.00 4

Shaft Machined

- - - Grind Diameters - - - - - -

$21.43 Operation FM Rocker Piston, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Shaft Machined

$21.43 Material Mod. FM Rocker Piston, Grind OD 0-1 Inch 1.0000 sec 1.0000 sec $0.00 $0.01 4

Shaft Machined

$21.43 Operation FM Rocker Piston, CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Shaft Machined

$21.43 Material Mod. FM Rocker Piston, Grind OD 0-1 Inch 1.0000 sec 1.0000 sec $0.00 $0.01 4

Shaft Machined

$21.43 Operation Operation FM Rocker Piston, FM Rocker Piston, Auto Tool Change Auto Tool Change 5.0000 sec 5.0000 sec 5.0000 sec 5.0000 sec $0.00 $0.03 4

Shaft Machined

$21.43 Material Mod. FM Rocker Piston, Cut to Length 1.0000 sec 1.0000 sec $0.00 $0.01 4

Shaft Machined

$21.43 Operation FM Rocker Piston, Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 4

Shaft Machined

$21.43 Operation FM Rocker Piston, Auto Eject Part 0.5000 sec 0.5000 sec $0.00 $0.00 4

Shaft Machined

$21.43 Operation FM Rocker Piston, Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Shaft Machined

- - - Batch Type Washer - - - - - -

- - - 5-10 min cycle time - - - - - -

- - - Basket Size 15.75x18.50x25.50 - - - - - -

inches x 2

$10.75 Operation FM Rocker Piston, Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 4

Shaft Washed

$10.75 Operation FM Rocker Piston, Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 4

Shaft Washed

$10.75 Operation FM Rocker Piston, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 4

Shaft Washed

Design Profit ®
Page 31 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$46.52 Operation FM Rocker Piston, Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 4

Shaft

$46.52 Material Mod. FM Rocker Piston, Induction Harden 2.0000 sec 2.0000 sec $0.00 $0.03 4

Shaft

$46.52 Operation FM Rocker Piston, Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Shaft

$46.52 P.-P. Part FM Rocker Piston FM Rocker Piston Cup FM Rocker Piston, 3.0000 sec 3.0000 sec - $0.07 4

Cup

$46.52 Tool FM Rocker Piston First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 4

Cup

$15.50 P.-P. Part FM Rocker Piston FM Rocker Piston Cup, Stamped FM Rocker Piston 3.0000 sec 3.0000 sec - $0.04 4

Cup Cup, Stamped

$15.50 Tool FM Rocker Piston Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 4

Cup, Stamped

$15.50 Part FM Rocker Piston FM Rocker Piston Cup, Material FM Rocker Piston 0.0000 sec 0.6000 sec $0.01 $0.00 4

Cup, Stamped Cup, Material

- - - Blank weight .013 lbs - - - - - -

- - - Press Size 25 Ton Progressive - - - - - -

Press

- - - Part Size after stamping (24.95 - - - - - -

Dia by 6.40 H)mm

$46.52 Operation Operation FM Rocker Piston FM Rocker Piston Load Part Load Part 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec $0.00 $0.04 4

Cup

$46.52 Material Mod. FM Rocker Piston Induction Harden 2.0000 sec 2.0000 sec $0.00 $0.03 4

Cup

$46.52 Operation FM Rocker Piston Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Cup

$83.31 Part FM Rocker Piston FM Rocker Piston, Clip FM Rocker Piston, 9.0000 sec 9.0000 sec $0.02 $0.21 4

Clip

$83.31 Tool FM Rocker Piston Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.07 4

$83.31 Fastening FM Rocker Piston Insert Retainer 4.0000 sec 4.0000 sec $0.00 $0.09 4

$35.51 Part FM Solenoid FM Rocker Spring FM Rocker Spring 3.0000 sec 3.0000 sec $0.23 $0.03 4

Housing Assy

$83.31 Subassembly FM Solenoid FM Roller Rocker FM Roller Rocker 3.0000 sec 3.0000 sec $2.00 $0.03 4

Housing Assy

$35.51 Operation FM Solenoid Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing Assy

$35.51 Operation FM Solenoid Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

- - - Install Pressure Relief System - - - - - -

Design Profit ®
Page 32 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$35.51 Operation FM Solenoid Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

$35.51 Part FM Solenoid FM Pressure Relief O-Ring FM Pressure 8.0000 sec 8.0000 sec $0.04 $0.08 4

Housing Assy Relief O-Ring

$55.17 P.-P. Part FM Solenoid FM Pressure Relief Piston FM Pressure 10.0000 sec 10.0000 sec - $0.10 4

Housing Assy Relief Piston

$55.17 Tool FM Pressure Plating Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 4

Relief Piston

$46.52 P.-P. Part FM Pressure FM Pressure Relief Piston, FM Pressure 3.0000 sec 3.0000 sec - $0.05 4

Relief Piston Hardened Relief Piston, 

Hardened

$46.52 Tool FM Pressure First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 4

Relief Piston, 

Hardened

$41.20 P.-P. Part FM Pressure FM Pressure Relief Piston, FM Pressure 3.0000 sec 3.0000 sec - $0.04 4

Relief Piston, Washed Relief Piston, 

Hardened Washed

$41.20 Tool FM Pressure Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 4

Relief Piston, DRY

Washed

$41.20 P.-P. Part FM Pressure FM Pressure Relief Piston, FM Pressure 3.0000 sec 3.0000 sec - $0.03 4

Relief Piston, Machined Relief Piston, 

Washed Machined

$41.20 Tool FM Pressure Grinding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 4

Relief Piston, 

Machined

$15.50 P.-P. Part FM Pressure FM Pressure Relief Piston, FM Pressure 3.0000 sec 3.0000 sec - $0.03 4

Relief Piston, Stamped Relief Piston, 

Machined Stamped

$15.50 Tool FM Pressure Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 4

Relief Piston, 

Stamped

$15.50 Part FM Pressure FM Pressure Relief Piston, FM Pressure 0.0000 sec 0.6000 sec $0.01 $0.00 4

Relief Piston, Material Relief Piston, 

Stamped Material

- - - Blank weight ,.015 lbs - - - - - -

- - - Press Size 25 Ton Progressive - - - - - -

- - - Part Size after stamping (16 Di by - - - - - -

by 17.17 H)mm

$41.20 Operation FM Pressure Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 4

Relief Piston, 

Machined

Design Profit ®
Page 33 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$41.20 Operation FM Pressure Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 4

Relief Piston, 

Machined

$41.20 Material Mod. FM Pressure Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Relief Piston, 

Machined

$41.20 Operation FM Pressure Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 4

Relief Piston, 

Machined

$41.20 Operation FM Pressure Auto Eject Part 0.5000 sec 0.5000 sec $0.00 $0.01 4

Relief Piston, 

Machined

- - - Batch Type Washer - - - - - -

- - - 5-10 min cycle time - - - - - -

- - - Basket Size 15.75x18.50x25.50 - - - - - -

inches x 2

$41.20 Operation FM Pressure Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 4

Relief Piston, 

Washed

$41.20 Operation FM Pressure Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.06 4

Relief Piston, 

Washed

$41.20 Operation FM Pressure Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 4

Relief Piston, 

Washed

$46.52 Operation FM Pressure Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 4

Relief Piston, 

Hardened

$46.52 Material Mod. FM Pressure Induction Harden 2.0000 sec 2.0000 sec $0.00 $0.03 4

Relief Piston, 

Hardened

$46.52 Operation FM Pressure Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Relief Piston, 

Hardened

$55.17 Operation FM Pressure Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 4

Relief Piston

$55.17 Operation FM Pressure Electroplate Process 0.3026 sec 1.8156 sec $0.00 $0.03 4

Relief Piston

$55.17 Operation FM Pressure Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Relief Piston

$35.51 Part FM Solenoid FM Pressure Relief Spring FM Pressure 8.0000 sec 8.0000 sec $0.07 $0.08 4

Housing Assy Relief Spring

Design Profit ®
Page 34 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$55.17 P.-P. Part FM Solenoid FM Pressure Relief Spring Seat FM Pressure 12.0000 sec 12.0000 sec - $0.12 4

Housing Assy Relief Spring Seat

$55.17 Tool FM Pressure Plating Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 4

Relief Spring Seat

$46.52 P.-P. Part FM Pressure FM Pressure Relief Spring Seat, FM Pressure 3.0000 sec 3.0000 sec - $0.05 4

Relief Spring Seat Hardened Relief Spring 

Seat, Hardened

$46.52 Tool FM Pressure FM Pressure First Fixture First Fixture 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 4

Relief Spring 

Seat, Hardened

$41.20 P.-P. Part FM Pressure FM Pressure Relief Spring Seat, FM Pressure 3.0000 sec 3.0000 sec - $0.04 4

Relief Spring Washed Relief Spring 

Seat, Hardened Seat, Washed

$41.20 Tool FM Pressure Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 4

Relief Spring DRY

Seat, Washed

$41.20 P.-P. Part FM Pressure FM Pressure Relief Spring Seat, FM Pressure 3.0000 sec 3.0000 sec - $0.03 4

Relief Spring Machined Relief Spring 

Seat, Washed Seat, Machined1

$41.20 Tool FM Pressure Grinding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 4

Relief Spring 

Seat, Machined

$15.50 P.-P. Part FM Pressure FM Pressure Relief Spring Seat, FM Pressure 3.0000 sec 3.0000 sec - $0.03 4

Relief Spring Stamped Relief Spring 

Seat, Machined Seat, Stamped

Design Profit ®

Page 35 of #
Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$15.50 Tool FM Pressure Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 4

Relief Spring 

Seat, Stamped

$15.50 Part FM Pressure FM Pressure Relief Spring Seat, FM Pressure 0.0000 sec 0.6000 sec $0.01 $0.00 4

Relief Spring Material Relief Spring 

Seat, Stamped Seat, Material

- - - Blank weight .015 lbs - - - - - -

- - - Press Size 25 Ton Progressive - - - - - -

- - - Part Size after stamping (16 Di by - - - - - -

by 17.17 H)mm

$41.20 Operation FM Pressure Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 4

Relief Spring 

Seat, Machined

$41.20 Operation FM Pressure Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 4

Relief Spring 

Seat, Machined

$41.20 Material Mod. FM Pressure Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Relief Spring 

Seat, Machined

$41.20 Operation FM Pressure Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 4

Relief Spring 

Seat, Machined

$41.20 Operation FM Pressure Auto Eject Part 0.5000 sec 0.5000 sec $0.00 $0.01 4

Relief Spring 

Seat, Machined

- - - Batch Type Washer - - - - - -

- - - 5-10 min cycle time - - - - - -

- - - Basket Size 15.75x18.50x25.50 - - - - - -

inches x 2

$41.20 Operation FM Pressure Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 4

Relief Spring 

Seat, Washed

$41.20 Operation FM Pressure Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.06 4

Relief Spring 

Seat, Washed

$41.20 Operation FM Pressure Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 4

Relief Spring 

Seat, Washed

$46.52 Operation FM Pressure Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 4

Relief Spring 

Seat, Hardened

Design Profit ®
Page 36 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$46.52 Material Mod. FM Pressure Induction Harden 2.0000 sec 2.0000 sec $0.00 $0.03 4

Relief Spring 

Seat, Hardened

$46.52 Operation FM Pressure Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Relief Spring 

Seat, Hardened

$55.17 Operation FM Pressure Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 4

Relief Spring Seat

$55.17 Operation FM Pressure Electroplate Process 0.3026 sec 1.8156 sec $0.00 $0.03 4

Relief Spring Seat

$55.17 Operation FM Pressure Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Relief Spring Seat

$35.51 Part FM Solenoid FM Pressure Relief Clip FM Pressure 3.0000 sec 3.0000 sec $0.01 $0.03 4

Housing Assy Relief Clip

$35.51 Tool FM Solenoid Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

$35.51 Fastening FM Solenoid Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 4

Housing Assy

- - - Install Check Valve - - - - - -

$0.00 Subassembly FM Solenoid FM Check Valve FM Check Valve 3.0000 sec 3.0000 sec $0.12 $0.03 8

Housing Assy

- - - Install Valve Actuation Piston Install Valve Actuation Piston - - - - - -

$35.51 Subassembly FM Solenoid FM Valve Actuation Piston FM Valve 8.0000 sec 8.0000 sec - $0.08 8

Housing Assy Actuation Piston

$35.51 Tool FM Valve First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston

- - - Install Clip over Cap - - - - - -

$46.52 P.-P. Part FM Valve FM Valve Actuation Piston, Cap FM Valve 3.0000 sec 3.0000 sec - $0.03 8

Actuation Piston Actuation Piston, 

Cap

$46.52 Tool FM Valve First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, 

Cap

$41.20 P.-P. Part FM Valve FM Valve Actuation Piston, Cap FM Valve 3.0000 sec 3.0000 sec - $0.04 8

Actuation Piston, Blank Machined Actuation Piston, 

Cap Cap Blank 

Machined

$41.20 Tool FM Valve EC-300-ML Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, Machine

Cap Blank 

Machined

Design Profit ®
Page 37 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

###### P.-P. Part FM Valve FM Valve Actuation Piston, Cap FM Valve 3.0000 sec 3.0000 sec - $0.03 8

Actuation Piston, Blank Actuation Piston, 

Cap Blank Cap Blank

Machined

###### Tool FM Valve Forging Press 500 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, 

Cap Blank

###### Part FM Valve FM Valve Actuation Piston, Cap FM Valve 0.0000 sec 0.0000 sec $0.01 $0.00 8

Actuation Piston, Blank Material Actuation Piston, 

Cap Blank Cap Blank 

Material

###### Operation FM Valve Load Part 3.0000 sec 3.0000 sec $0.00 $0.10 8

Actuation Piston, 

Cap Blank

- - - Raw Material Req 0.02 lbs Actual - - - - - -

+ %

- - - Box Size 11mm Dia x 14.5mm L - - - - - -

- - - 3 hits based on rough - near net - - - - - -

shape

###### Material Mod. FM Valve Forge 500T 0.8500 sec 0.8500 sec $0.00 $0.03 8

Actuation Piston, 

Cap Blank

###### Operation FM Valve Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.10 8

Actuation Piston, 

Cap Blank

###### Material Mod. FM Valve Forge 500T 0.8500 sec 0.8500 sec $0.00 $0.03 8

Actuation Piston, 

Cap Blank

###### Operation FM Valve Unload Part 2.0000 sec 2.0000 sec $0.00 $0.06 8

Actuation Piston, 

Cap Blank

$41.20 Operation FM Valve Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 8

Actuation Piston, 

Cap Blank 

Machined

$41.20 Operation FM Valve Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 8

Actuation Piston, 

Cap Blank 

Machined

$41.20 Material Mod. FM Valve Cut Small Groove 0.5000 sec 0.5000 sec $0.00 $0.01 8

Actuation Piston, 

Cap Blank 

Machined

Design Profit ®
Page 38 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$41.20 Operation FM Valve Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 8

Actuation Piston, 

Cap Blank 

Machined

$41.20 Material Mod. FM Valve Grind ID 3.0000 sec 3.0000 sec $0.00 $0.03 8

Actuation Piston, 

Cap Blank 

Machined

$41.20 Operation FM Valve Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Cap Blank 

Machined

$41.20 Operation FM Valve Auto Eject Part 0.5000 sec 0.5000 sec $0.00 $0.01 8

Actuation Piston, 

Cap Blank 

Machined

$41.20 Operation FM Valve Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 8

Actuation Piston, 

Cap Blank 

Machined

$46.52 Operation FM Valve Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 8

Actuation Piston, 

Cap

$46.52 Material Mod. FM Valve Induction Harden 2.0000 sec 2.0000 sec $0.00 $0.03 8

Actuation Piston, 

Cap

$46.52 Operation FM Valve Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 8

Actuation Piston, 

Cap

$35.51 Part FM Valve FM Valve Actuation Piston, Clip FM Valve 5.0000 sec 5.0000 sec $0.02 $0.05 8

Actuation Piston Actuation Piston, 

Clip

$35.51 Tool FM Valve Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.03 8

Actuation Piston

$35.51 Fastening FM Valve Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 8

Actuation Piston

- - - Press Spring Guide into Long Pin - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®
Page 39 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$55.17 P.-P. Part FM Valve FM Valve Actuation Piston, Long FM Valve 3.0000 sec 3.0000 sec - $0.03 8

Actuation Piston Pin Actuation Piston, 

Long Pin

$55.17 Tool FM Valve Plating Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, 

Long Pin

$10.75 P.-P. Part FM Valve FM Valve Actuation Piston, Long FM Valve 3.0000 sec 3.0000 sec - $0.05 8

Actuation Piston, Pin Washed Actuation Piston, 

Long Pin Long Pin Washed

$10.75 Tool FM Valve Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, DRY

Long Pin Washed

$41.20 P.-P. Part FM Valve FM Valve Actuation Piston, Long FM Valve 3.0000 sec 3.0000 sec - $0.01 8

Actuation Piston, Pin Ground Actuation Piston, 

Long Pin Washed Long Pin Ground

$41.20 Tool FM Valve Grinding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, 

Long Pin Ground

$46.52 P.-P. Part FM Valve FM Valve Actuation Piston, FM Valve 3.0000 sec 3.0000 sec - $0.03 8

Actuation Piston, Hardened Actuation Piston, 

Long Pin Ground Hardened

$46.52 Tool FM Valve First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, 

Hardened

$41.20 P.-P. Part FM Valve FM Valve Actuation Piston, Long FM Valve 3.0000 sec 3.0000 sec - $0.04 8

Actuation Piston, Pin Blank Machined Actuation Piston, 

Hardened Long Pin Blank 

Machined

$41.20 Tool FM Valve EC-300-ML Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, Machine

Long Pin Blank 

Machined

###### P.-P. Part FM Valve FM Valve Actuation Piston, Long FM Valve 3.0000 sec 3.0000 sec - $0.03 8

Actuation Piston, Pin Blank Actuation Piston, 

Long Pin Blank Long Pin Blank

Machined

###### Tool FM Valve Forging Press 500 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, 

Long Pin Blank

Design Profit ®
Page 40 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

###### Part FM Valve FM Valve Actuation Piston, Long FM Valve 0.0000 sec 0.0000 sec $0.02 $0.00 8

Actuation Piston, Pin Blank Material Actuation Piston, 

Long Pin Blank Long Pin Blank 

Material

###### Operation FM Valve Load Part 3.0000 sec 3.0000 sec $0.00 $0.10 8

Actuation Piston, 

Long Pin Blank

- - - Raw Material Req 0.03 lbs Actual - - - - - -

+ %

- - - Box Size 8.6mm Dia x 25mm L - - - - - -

- - - 2 hits based on rough - near net - - - - - -

shape

###### Material Mod. FM Valve Forge 500T 0.8500 sec 0.8500 sec $0.00 $0.03 8

Actuation Piston, 

Long Pin Blank

- - - 2nd hit - - - - - -

###### Operation FM Valve Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.10 8

Actuation Piston, 

Long Pin Blank

###### Material Mod. FM Valve Forge 500T 0.8500 sec 0.8500 sec $0.00 $0.03 8

Actuation Piston, 

Long Pin Blank

- - - 3rd hit - - - - - -

###### Operation FM Valve Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.10 8

Actuation Piston, 

Long Pin Blank

###### Material Mod. FM Valve Forge 500T 0.8500 sec 0.8500 sec $0.00 $0.03 8

Actuation Piston, 

Long Pin Blank

###### Operation FM Valve Unload Part 2.0000 sec 2.0000 sec $0.00 $0.06 8

Actuation Piston, 

Long Pin Blank

$41.20 Operation FM Valve Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 8

Actuation Piston, 

Long Pin Blank 

Machined

$41.20 Operation FM Valve Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 8

Actuation Piston, 

Long Pin Blank 

Machined

Design Profit ®
Page 41 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$41.20 Material Mod. FM Valve Drill Oil Hole 2.0000 sec 2.0000 sec $0.00 $0.02 8

Actuation Piston, 

Long Pin Blank 

Machined

$41.20 Operation FM Valve Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Long Pin Blank 

Machined

$41.20 Operation FM Valve Auto Eject Part 0.5000 sec 0.5000 sec $0.00 $0.01 8

Actuation Piston, 

Long Pin Blank 

Machined

$46.52 Operation FM Valve Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 8

Actuation Piston, 

Hardened

$46.52 Material Mod. FM Valve Induction Harden 2.0000 sec 2.0000 sec $0.00 $0.03 8

Actuation Piston, 

Hardened

$46.52 Operation FM Valve Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 8

Actuation Piston, 

Hardened

$41.20 Operation FM Valve Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 8

Actuation Piston, 

Long Pin Ground

$41.20 Operation FM Valve Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 8

Actuation Piston, 

Long Pin Ground

$41.20 Material Mod. FM Valve Grind OD 0-1 Inch 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Long Pin Ground

$41.20 Operation FM Valve Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Long Pin Ground

$41.20 Operation FM Valve Auto Eject Part 0.5000 sec 0.5000 sec $0.00 $0.01 8

Actuation Piston, 

Long Pin Ground

- - - Batch Type Washer - - - - - -

- - - 5-10 min cycle time - - - - - -

- - - Basket Size 15.75x18.50x25.50 - - - - - -

inches x 2

$10.75 Operation FM Valve Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 8

Actuation Piston, 

Long Pin Washed

Design Profit ®
Page 42 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$10.75 Operation FM Valve Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 8

Actuation Piston, 

Long Pin Washed

$10.75 Operation FM Valve Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 8

Actuation Piston, 

Long Pin Washed

$55.17 Operation FM Valve Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 8

Actuation Piston, 

Long Pin

$55.17 Operation FM Valve Electroplate Process 0.3026 sec 1.8156 sec $0.00 $0.03 8

Actuation Piston, 

Long Pin

$55.17 Operation FM Valve Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 8

Actuation Piston, 

Long Pin

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 43 of #

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$10.75 P.-P. Part FM Valve FM Valve Actuation Piston, FM Valve 6.0000 sec 6.0000 sec - $0.06 8

Actuation Piston Spring Guide Actuation Piston, 

Spring Guide

$10.75 Tool FM Valve Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, DRY

Spring Guide

$15.50 P.-P. Part FM Valve FM Valve Actuation Piston, FM Valve 3.0000 sec 3.0000 sec - $0.01 8

Actuation Piston, Spring Guide Stamped Actuation Piston, 

Spring Guide Spring Guide 

Stamped

$15.50 Tool FM Valve Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, 

Spring Guide 

Stamped

$15.50 Part FM Valve FM Valve Actuation Piston, FM Valve 0.0000 sec 0.6000 sec $0.01 $0.00 8

Actuation Piston, Spring Guide Material Actuation Piston, 

Spring Guide Spring Guide 

Stamped Material

- - - Blank weight .001lbs - - - - - -

- - - Press Size 25 Ton Progressive - - - - - -

- - - Part Size after stamping (6.5 Dia - - - - - -

by 3 H)mm

$10.75 Operation FM Valve Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 8

Actuation Piston, 

Spring Guide

$10.75 Operation FM Valve Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 8

Actuation Piston, 

Spring Guide

$10.75 Operation FM Valve Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 8

Actuation Piston, 

Spring Guide

$35.51 Tool FM Valve Press 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston

$35.51 Fastening FM Valve Press to Depth 3.0000 sec 3.0000 sec $0.00 $0.03 8

Actuation Piston

- - - Install Spring, Long Pin and Cap - - - - - -

into Housing

$35.51 Part FM Valve FM Valve Actuation Piston, FM Valve 4.0000 sec 4.0000 sec $0.01 $0.04 8

Actuation Piston Spring Actuation Piston, 

Spring

Design Profit ®
Page 44 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$10.75 P.-P. Part FM Valve FM Valve Actuation Piston, FM Valve 4.0000 sec 4.0000 sec - $0.04 8

Actuation Piston Housing Actuation Piston, 

Housing

$10.75 Tool FM Valve Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, DRY

Housing

$41.20 P.-P. Part FM Valve FM Valve Actuation Piston, FM Valve 3.0000 sec 3.0000 sec - $0.01 8

Actuation Piston, Ground Actuation Piston, 

Housing Ground

$41.20 Tool FM Valve Grinding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, 

Ground

$46.52 P.-P. Part FM Valve FM Valve Actuation Piston, FM Valve 3.0000 sec 3.0000 sec - $0.03 8

Actuation Piston, Housing Heat Treated Actuation Piston, 

Ground Housing Heat 

Treated

$46.52 Tool FM Valve First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, 

Housing Heat 

Treated

$42.68 P.-P. Part FM Valve FM Valve Actuation Piston, FM Valve 3.0000 sec 3.0000 sec - $0.04 8

Actuation Piston, Housing Machined Actuation Piston, 

Housing Heat Housing Machined

Treated

$42.68 Tool FM Valve CNC TL-15 4 Axis Twin Spindle 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, Lathe - Auto Load

Housing Machined

- - - Includes Bar Feeder - - - - - -

$42.68 Part FM Valve FM Valve Actuation Piston, FM Valve 0.0000 sec 0.0000 sec $0.11 $0.00 8

Actuation Piston, Housing Material Actuation Piston, 

Housing Machined Housing Material

- - - Bar stock weight .18 lbs. - - - - - -

- - - Box size of finished part - - - - - -

17.8Dmm x 40.5Lmm

$42.68 Operation FM Valve Bar Feeder Load & Clamp 3.0000 sec 3.0000 sec $0.00 $0.04 8

Actuation Piston, 

Housing Machined

- - - ID Machining - - - - - -

$42.68 Material Mod. FM Valve Drill Hole 30 - 60mm 2.0000 sec 2.0000 sec $0.00 $0.02 8

Actuation Piston, 

Housing Machined

Design Profit ®
Page 45 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$42.68 Operation FM Valve Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 8

Actuation Piston, 

Housing Machined

$42.68 Material Mod. FM Valve Bore Hole 30-60mm 2.0000 sec 2.0000 sec $0.00 $0.02 8

Actuation Piston, 

Housing Machined

$42.68 Operation FM Valve Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 8

Actuation Piston, 

Housing Machined

$42.68 Material Mod. FM Valve Ream Hole 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Housing Machined

$42.68 Operation FM Valve Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 8

Actuation Piston, 

Housing Machined

$42.68 Material Mod. FM Valve Turn Internal Groove 3.0000 sec 3.0000 sec $0.00 $0.04 8

Actuation Piston, 

Housing Machined

$42.68 Operation FM Valve Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 8

Actuation Piston, 

Housing Machined

$42.68 Material Mod. Material Mod. FM Valve FM Valve Rough Turn ID Rough Turn ID 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec $0.00 $0.04 8

Actuation Piston, 

Housing Machined

$42.68 Operation FM Valve CDI 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Housing Machined

$42.68 Material Mod. FM Valve Finish Turn ID 2.0000 sec 2.0000 sec $0.00 $0.02 8

Actuation Piston, 

Housing Machined

- - - OD Machining - - - - - -

$42.68 Operation FM Valve Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 8

Actuation Piston, 

Housing Machined

$42.68 Material Mod. FM Valve Turn OD 30-60mm 2.0000 sec 2.0000 sec $0.00 $0.02 8

Actuation Piston, 

Housing Machined

$42.68 Operation FM Valve CDI 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Housing Machined

$42.68 Material Mod. FM Valve Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Housing Machined

Design Profit ®
Page 46 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$42.68 Operation FM Valve Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 8

Actuation Piston, 

Housing Machined

$42.68 Material Mod. FM Valve Turn O-Ring Groove 2.0000 sec 2.0000 sec $0.00 $0.02 8

Actuation Piston, 

Housing Machined

$42.68 Operation FM Valve CDI 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Housing Machined

$42.68 Material Mod. FM Valve Turn O-Ring Groove 2.0000 sec 2.0000 sec $0.00 $0.02 8

Actuation Piston, 

Housing Machined

$42.68 Operation FM Valve Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 8

Actuation Piston, 

Housing Machined

$42.68 Material Mod. FM Valve Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Housing Machined

$42.68 Operation FM Valve CDI 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Housing Machined

$42.68 Material Mod. Material Mod. FM Valve FM Valve Turn OD 1-30mm Turn OD 1-30mm 1.0000 sec 1.0000 sec 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Housing Machined

$42.68 Operation FM Valve CDI 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Housing Machined

$42.68 Material Mod. FM Valve Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Housing Machined

$42.68 Operation FM Valve Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 8

Actuation Piston, 

Housing Machined

$42.68 Material Mod. FM Valve Turn Threads 2.0000 sec 2.0000 sec $0.00 $0.02 8

Actuation Piston, 

Housing Machined

- - - Cut Flats - - - - - -

$42.68 Operation FM Valve Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 8

Actuation Piston, 

Housing Machined

$42.68 Material Mod. FM Valve Machine Wrench Flats 1.0000 sec 1.0000 sec $0.00 $0.01 48

Actuation Piston, 

Housing Machined

Design Profit ®
Page 47 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$42.68 Operation FM Valve CDI 1.0000 sec 1.0000 sec $0.00 $0.01 40

Actuation Piston, 

Housing Machined

- - - Cut Face Slot - - - - - -

$42.68 Operation FM Valve Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 8

Actuation Piston, 

Housing Machined

$42.68 Material Mod. FM Valve Cut slot 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Housing Machined

- - - Hole Drilling - - - - - -

$42.68 Operation FM Valve Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 8

Actuation Piston, 

Housing Machined

$42.68 Material Mod. FM Valve Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Housing Machined

$42.68 Operation FM Valve Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 8

Actuation Piston, 

Housing Machined

$42.68 Material Mod. FM Valve Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 48

Actuation Piston, 

Housing Machined

$42.68 Operation FM Valve CDI 1.0000 sec 1.0000 sec $0.00 $0.01 40

Actuation Piston, 

Housing Machined

$42.68 Material Mod. FM Valve Cut to Length 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Housing Machined

$42.68 Operation FM Valve Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 8

Actuation Piston, 

Housing Machined

$42.68 Operation FM Valve Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Housing Machined

$42.68 Operation FM Valve Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 8

Actuation Piston, 

Housing Machined

$46.52 Operation FM Valve Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 8

Actuation Piston, 

Housing Heat 

Treated
Design Profit

®

Page 48 of#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$46.52 Material Mod. FM Valve Induction Harden 2.0000 sec 2.0000 sec $0.00 $0.03 8

Actuation Piston, 

Housing Heat 

Treated

$46.52 Operation FM Valve Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 8

Actuation Piston, 

Housing Heat 

Treated

$41.20 Operation FM Valve Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 8

Actuation Piston, 

Ground

$41.20 Operation FM Valve Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 8

Actuation Piston, 

Ground

$41.20 Material Mod. FM Valve Grind OD 0-1 Inch 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Ground

$41.20 Operation FM Valve Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Ground

$41.20 Operation FM Valve Auto Eject Part 0.5000 sec 0.5000 sec $0.00 $0.01 8

Actuation Piston, 

Ground

$10.75 Operation FM Valve Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 8

Actuation Piston, 

Housing

$10.75 Operation FM Valve Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 8

Actuation Piston, 

Housing

$10.75 Operation FM Valve Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 8

Actuation Piston, 

Housing

- - - Install Short Pin into Housing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$55.17 P.-P. Part FM Valve FM Valve Actuation Piston, Short FM Valve 3.0000 sec 3.0000 sec - $0.03 8

Actuation Piston Pin Actuation Piston, 

Short Pin

Design Profit ®
Page 49 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$55.17 Tool FM Valve Plating Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, 

Short Pin

$10.75 P.-P. Part FM Valve FM Valve Actuation Piston, Short FM Valve 3.0000 sec 3.0000 sec - $0.05 8

Actuation Piston, Pin Washed Actuation Piston, 

Short Pin Short Pin Washed

$10.75 Tool FM Valve Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, DRY

Short Pin Washed

$41.20 P.-P. Part FM Valve FM Valve Actuation Piston, Short FM Valve 3.0000 sec 3.0000 sec - $0.01 8

Actuation Piston, Pin Blank Machine Actuation Piston, 

Short Pin Washed Short Pin Blank 

Machine

$41.20 Tool FM Valve Grinding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, 

Short Pin Blank 

Machine

$46.52 P.-P. Part FM Valve FM Valve Actuation Piston, Short FM Valve 3.0000 sec 3.0000 sec - $0.03 8

Actuation Piston, Pin Hardened Actuation Piston, 

Short Pin Blank Short Pin 

Machine Hardened1

$46.52 Tool FM Valve First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, 

Short Pin 

Hardened

###### P.-P. Part FM Valve FM Valve Actuation Piston, Short FM Valve 3.0000 sec 3.0000 sec - $0.04 8

Actuation Piston, Pin Blank Actuation Piston, 

Short Pin Short Pin Blank

Hardened

###### Tool FM Valve Forging Press 500 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 8

Actuation Piston, 

Short Pin Blank

###### Part FM Valve FM Valve Actuation Piston, Short FM Valve 0.0000 sec 0.0000 sec $0.01 $0.00 8

Actuation Piston, Pin Material Actuation Piston, 

Short Pin Blank Short Pin Material

###### Operation FM Valve Load Part 3.0000 sec 3.0000 sec $0.00 $0.10 8

Actuation Piston, 

Short Pin Blank

- - - Raw Material Req 0.01 lbs Actual - - - - - -

+ %

- - - Box Size 8.6mm Dia x 10.2mm L - - - - - -

- - - 1 hit based on rough - near net - - - - - -

shape

Design Profit ®
Page 50 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

###### Material Mod. FM Valve Forge 500T 0.8500 sec 0.8500 sec $0.00 $0.03 8

Actuation Piston, 

Short Pin Blank

$46.52 Operation FM Valve Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 8

Actuation Piston, 

Short Pin 

Hardened

$46.52 Material Mod. FM Valve Induction Harden 2.0000 sec 2.0000 sec $0.00 $0.03 8

Actuation Piston, 

Short Pin 

Hardened

$46.52 Operation FM Valve Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 8

Actuation Piston, 

Short Pin 

Hardened

$46.52 Operation FM Valve Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 8

Actuation Piston, 

Short Pin 

Hardened

$41.20 Operation FM Valve Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 8

Actuation Piston, 

Short Pin Blank 

Machine

$41.20 Operation FM Valve Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 8

Actuation Piston, 

Short Pin Blank 

Machine

$41.20 Material Mod. FM Valve Grind OD 0-1 Inch 1.0000 sec 1.0000 sec $0.00 $0.01 8

Actuation Piston, 

Short Pin Blank 

Machine

$41.20 Operation FM Valve Auto Eject Part 0.5000 sec 0.5000 sec $0.00 $0.01 8

Actuation Piston, 

Short Pin Blank 

Machine

$10.75 Operation FM Valve Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 8

Actuation Piston, 

Short Pin Washed

$10.75 Operation FM Valve Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 8

Actuation Piston, 

Short Pin Washed

Design Profit ®
Page 51 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$10.75 Operation FM Valve Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 8

Actuation Piston, 

Short Pin Washed

$55.17 Operation FM Valve Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 8

Actuation Piston, 

Short Pin

$55.17 Operation FM Valve Electroplate Process 0.3026 sec 1.8156 sec $0.00 $0.03 8

Actuation Piston, 

Short Pin

$55.17 Operation FM Valve Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 8

Actuation Piston, 

Short Pin

- - - Install O-Rings - - - - - -

$35.51 Part FM Valve FM Valve Actuation Piston, FM Valve 6.0000 sec 6.0000 sec $0.04 $0.06 8

Actuation Piston Yellow O-Ring Actuation Piston, 

Yellow O-Ring

$35.51 Fastening FM Valve Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 8

Actuation Piston

$35.51 Part FM Valve FM Valve Actuation Piston, Black FM Valve 6.0000 sec 6.0000 sec $0.04 $0.06 8

Actuation Piston O-Ring Actuation Piston, 

Black O-Ring

$35.51 Fastening Fastening FM Valve FM Valve Push In Place Push In Place 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec $0.00 $0.02 8

Actuation Piston

$35.51 Tool FM Solenoid Power Tool 4.0000 sec 4.0000 sec $0.00 $0.04 1

Housing Assy

$35.51 Fastening FM Solenoid Power Screw 4.0000 sec 4.0000 sec $0.00 $0.04 8

Housing Assy

$35.51 Operation FM Solenoid Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing Assy

$35.51 Operation FM Solenoid Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

- - - Install Solenoid - - - - - -

$35.51 Operation FM Solenoid Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®
Page 52 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 53 of #

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$25.00 Subassembly FM Solenoid FM Oil Control Solenoid Asm FM Oil Control 6.0000 sec 6.0000 sec - $0.06 4

Housing Assy Solenoid Asm

$25.00 Tool FM Oil Control First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 4

Solenoid Asm

$35.51 Subassembly FM Oil Control FM Oil Control Solenoid FM Oil Control 3.0000 sec 3.0000 sec - $0.02 4

Solenoid Asm Solenoid1

$35.51 Tool FM Oil Control First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 4

Solenoid

$35.51 Subassembly FM Oil Control FM Solenoid Plunger Assy FM Solenoid 3.0000 sec 3.0000 sec - $0.03 4

Solenoid Plunger Assy

$35.51 Tool FM Solenoid FM Solenoid First Fixture First Fixture 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Assy

- - - Press Plunger Stop into Plunger - - - - - -

Housing

$55.17 P.-P. Part FM Solenoid FM Solenoid Plunger Housing FM Plunger 3.0000 sec 3.0000 sec - $0.03 4

Plunger Assy Housing

$55.17 Tool FM Solenoid Plating Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Housing

$10.75 P.-P. Part FM Solenoid FM Solenoid Plunger Housing, FM Solenoid 3.0000 sec 3.0000 sec - $0.05 4

Plunger Housing Washed Plunger Housing, 

Washed

$10.75 Tool FM Solenoid Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Housing, DRY

Washed

$42.68 P.-P. Part FM Solenoid FM Solenoid Plunger Housing, FM Solenoid 3.0000 sec 3.0000 sec - $0.01 4

Plunger Housing, Machined Plunger Housing, 

Washed Machined

$42.68 Tool FM Solenoid CNC TL-15 4 Axis Twin Spindle 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Housing, Lathe - Auto Load

Machined

Design Profit ®

Page 54 of #
Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$42.68 Part FM Solenoid FM Solenoid Plunger Housing, FM Solenoid 0.0000 sec 0.0000 sec $0.15 $0.00 4

Plunger Housing, Material Plunger Housing, 

Machined Material

- - - Includes Bar Feeder - - - - - -

- - - Bar stock weight .20 lbs. - - - - - -

- - - Box size of finished part 25Dmm - - - - - -

x 23.5Lmm

$42.68 Operation FM Solenoid Bar Feeder Load & Clamp 3.0000 sec 3.0000 sec $0.00 $0.04 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 4

Plunger Housing, 

Machined

- - - Machine ID - - - - - -

$42.68 Material Mod. FM Solenoid Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 4

Plunger Housing, 

Machined

$42.68 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

Design Profit ®
Page 55 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$42.68 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 4

Plunger Housing, 

Machined

- - - Machine OD - - - - - -

$42.68 Material Mod. FM Solenoid Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Material Mod. FM Solenoid Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Material Mod. FM Solenoid Chamfer OD sml 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Material Mod. FM Solenoid Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Material Mod. FM Solenoid Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Material Mod. FM Solenoid Chamfer OD sml 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Material Mod. FM Solenoid Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

Design Profit ®
Page 56 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$42.68 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Material Mod. FM Solenoid Chamfer OD sml 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Material Mod. FM Solenoid Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Material Mod. FM Solenoid Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Material Mod. Material Mod. FM Solenoid FM Solenoid Chamfer OD sml Chamfer OD sml 1.0000 sec 1.0000 sec 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 4

Plunger Housing, 

Machined

$42.68 Material Mod. FM Solenoid Cut Small Groove 0.5000 sec 0.5000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Material Mod. FM Solenoid Cut Small Groove 0.5000 sec 0.5000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

- - - Drill 2 Cross Holes for 4 Features - - - - - -

$42.68 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 4

Plunger Housing, 

Machined

$42.68 Material Mod. FM Solenoid Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

Design Profit ®
Page 57 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$42.68 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Material Mod. FM Solenoid Drill Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

- - - Clamp Part w/Twin Spindle - - - - - -

$42.68 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 4

Plunger Housing, 

Machined

$42.68 Material Mod. FM Solenoid Cut to Length 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 4

Plunger Housing, 

Machined

$42.68 Material Mod. FM Solenoid Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid Auto Eject Part 0.5000 sec 0.5000 sec $0.00 $0.01 4

Plunger Housing, 

Machined

$42.68 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 4

Plunger Housing, 

Machined

$10.75 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 4

Plunger Housing, 

Washed

$10.75 Operation FM Solenoid Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 4

Plunger Housing, 

Washed

$10.75 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 4

Plunger Housing, 

Washed

$55.17 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 4

Plunger Housing

$55.17 Operation FM Solenoid Electroplate Process 0.9078 sec 1.8156 sec $0.00 $0.03 4

Plunger Housing

$55.17 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Plunger Housing

Design Profit ®
Page 58 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 59 of #

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$55.17 P.-P. Part FM Solenoid FM Solenoid Plunger Stop FM Plunger Stop 3.0000 sec 3.0000 sec - $0.03 4

Plunger Assy

$55.17 Tool FM Solenoid Plating Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Stop

$46.52 P.-P. Part FM Solenoid FM Solenoid Plunger Stop, FM Solenoid 4.0000 sec 4.0000 sec - $0.06 4

Plunger Stop Hardened Plunger Stop, 

Hardened

$46.52 Tool FM Solenoid First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Stop, 

Hardened

$20.90 P.-P. Part FM Solenoid FM Solenoid Plunger Stop, FM Solenoid 3.0000 sec 3.0000 sec - $0.04 4

Plunger Stop, Machined Plunger Stop, 

Hardened Machined

Design Profit ®

Page 60 of #

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$20.90 Tool FM Solenoid CNC Turning 2 Axis SL-10, 1.75" 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Stop, bar

Machined

###### P.-P. Part FM Solenoid FM Solenoid Plunger Stop, FM Solenoid 3.0000 sec 3.0000 sec - $0.02 4

Plunger Stop, Headed Plunger Stop, 

Machined Headed

###### Tool FM Solenoid Forging Press 500 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Stop, 

Headed

###### Part FM Solenoid FM Solenoid Plunger Stop, FM Solenoid 0.0000 sec 0.0000 sec $0.01 $0.00 4

Plunger Stop, Material Plunger Stop, 

Headed Material

- - - Bar stock weight .005 lbs. - - - - - -

- - - Box size of finished part 10Dmm - - - - - -

x 3Lmm

- - - 2 hits based on rough - near net - - - - - -

shape

###### Material Mod. FM Solenoid Forge 500T 0.8500 sec 0.8500 sec $0.00 $0.03 4

Plunger Stop, 

Headed

###### Operation FM Solenoid Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.10 4

Plunger Stop, 

Headed

###### Material Mod. FM Solenoid Forge 500T 0.8500 sec 0.8500 sec $0.00 $0.03 4

Plunger Stop, 

Headed

###### Operation FM Solenoid Auto Eject Part 0.5000 sec 0.5000 sec $0.00 $0.02 4

Plunger Stop, 

Headed

$20.90 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 4

Plunger Stop, 

Machined

$20.90 Operation FM Solenoid Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.02 4

Plunger Stop, 

Machined

- - - Machine ID - - - - - -

$20.90 Material Mod. FM Solenoid Drill Hole 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Stop, 

Machined

$20.90 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Plunger Stop, 

Machined

Design Profit ®
Page 61 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$20.90 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Stop, 

Machined

$20.90 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Plunger Stop, 

Machined

$20.90 Material Mod. FM Solenoid Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Stop, 

Machined

$20.90 Operation FM Solenoid Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Stop, 

Machined

$20.90 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 4

Plunger Stop, 

Machined

$20.90 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Plunger Stop, 

Machined

$46.52 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 4

Plunger Stop, 

Hardened

$46.52 Material Mod. Material Mod. FM Solenoid FM Solenoid Induction Harden Induction Harden 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec $0.00 $0.03 4

Plunger Stop, 

Hardened

$46.52 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Plunger Stop, 

Hardened

$55.17 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 4

Plunger Stop

$55.17 Operation FM Solenoid Electroplate Process 0.3026 sec 1.8156 sec $0.00 $0.03 4

Plunger Stop

$55.17 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Plunger Stop

$35.51 Tool FM Solenoid Press 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Assy

$35.51 Fastening FM Solenoid Press to Depth 3.0000 sec 3.0000 sec $0.00 $0.03 4

Plunger Assy

$35.51 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 4

Plunger Assy

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®
Page 62 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Install Plunger Pin Assy into Sol. - - - - - -

Plunger Assy

$35.51 Subassembly FM Solenoid FM Plunger Sub Assy FM Plunger Sub 3.0000 sec 3.0000 sec - $0.03 4

Plunger Assy Assy

$35.51 Tool FM Plunger Sub First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 4

Assy

$20.81 P.-P. Part FM Plunger Sub FM Solenoid Plunger Frame FM Solenoid 3.0000 sec 3.0000 sec - $0.03 4

Assy Plunger Frame

$20.81 Tool FM Solenoid Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Frame DRY

$42.18 P.-P. Part FM Solenoid FM Solenoid Plunger Frame, FM Solenoid 3.0000 sec 3.0000 sec - $0.02 4

Plunger Frame Stamped Plunger Frame, 

Stamped

$42.18 Tool FM Solenoid Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Frame, 

Stamped

$42.18 Part FM Solenoid FM Solenoid Plunger Frame, FM Solenoid 0.0000 sec 0.6000 sec $0.00 $0.01 4

Plunger Frame, Material Plunger Frame, 

Stamped Material

- - - Blank weight .005 lbs - - - - - -

- - - Press Size 25 Ton Progressive - - - - - -

- - - Part Size after stamping (12.1D - - - - - -

by 22 L)mm

$20.81 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 4

Plunger Frame

$20.81 Operation FM Solenoid Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.03 4

Plunger Frame

$20.81 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 4

Plunger Frame

$16.39 P.-P. Part FM Plunger Sub FM Solenoid Plunger Frame FM Solenoid 3.0000 sec 3.0000 sec - $0.03 4

Assy Piston Stop Plunger Frame 

Piston Stop

Design Profit ®

Page 63 of #
Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$16.39 Tool FM Solenoid Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Frame ton

Piston Stop

$16.39 Part FM Solenoid FM Solenoid Plunger Frame FM Solenoid 0.0000 sec 0.7030 sec $0.02 $0.00 4

Plunger Frame Piston Stop, Material Plunger Frame 

Piston Stop Piston Stop, 

Material

- - - Raw Material Req 0.001 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 11.5mm D x 4.1mm H - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$35.51 Subassembly FM Plunger Sub FM Solenoid Plunger Piston Assy FM Solenoid 3.0000 sec 3.0000 sec - $0.03 4

Assy Plunger Piston 

Assy

$35.51 Tool FM Solenoid First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Piston 

Assy

$55.17 P.-P. Part FM Solenoid FM Solenoid Plunger Piston Body FM Solenoid 3.0000 sec 3.0000 sec - $0.03 4

Plunger Piston Plunger Piston 

Assy Body

$55.17 Tool FM Solenoid Plating Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Piston 

Body

$46.52 P.-P. Part FM Solenoid FM Solenoid Plunger Piston FM Solenoid 3.0000 sec 3.0000 sec - $0.05 4

Plunger Piston Body, Hardened Plunger Piston 

Body Body, Hardened

$46.52 Tool FM Solenoid First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Piston 

Body, Hardened

$20.90 P.-P. Part FM Solenoid FM Solenoid Plunger Piston FM Solenoid 3.0000 sec 3.0000 sec - $0.04 4

Plunger Piston Body, Machined Plunger Piston 

Body, Hardened Body, Machined

$20.90 Tool FM Solenoid CNC Turning 2 Axis SL-10, 1.75" 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Piston bar

Body, Machined

Design Profit ®

Page 64 of #
Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

###### P.-P. Part FM Solenoid FM Solenoid Plunger Piston FM Solenoid 3.0000 sec 3.0000 sec - $0.02 4

Plunger Piston Body, Headed Plunger Piston 

Body, Machined Body, Headed

###### Tool FM Solenoid Forging Press 500 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Piston 

Body, Headed

###### Part FM Solenoid FM Solenoid Plunger Piston FM Solenoid 0.0000 sec 0.0000 sec $0.01 $0.00 4

Plunger Piston Body, Material Plunger Piston 

Body, Headed Body, Material

- - - Raw Material Req 0.02 lbs Actual - - - - - -

+ %

- - - Box Size 12mm Dia x 9.5mm L - - - - - -

- - - 2 hits based on rough - near net - - - - - -

shape

###### Material Mod. FM Solenoid Forge 500T 0.8500 sec 0.8500 sec $0.00 $0.03 4

Plunger Piston 

Body, Headed

- - - If 2nd hit required - - - - - -

###### Operation FM Solenoid Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.10 4

Plunger Piston 

Body, Headed

###### Material Mod. Material Mod. FM Solenoid FM Solenoid Forge 500T Forge 500T 0.8500 sec 0.8500 sec 0.8500 sec 0.8500 sec $0.00 $0.03 4

Plunger Piston 

Body, Headed

###### Operation FM Solenoid Auto Eject Part 0.5000 sec 0.5000 sec $0.00 $0.02 4

Plunger Piston 

Body, Headed

$20.90 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 4

Plunger Piston 

Body, Machined

$20.90 Material Mod. FM Solenoid Turn ID 0-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body, Machined

$20.90 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 4

Plunger Piston 

Body, Machined

$46.52 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 4

Plunger Piston 

Body, Hardened

$46.52 Material Mod. FM Solenoid Induction Harden 2.0000 sec 2.0000 sec $0.00 $0.03 4

Plunger Piston 

Body, Hardened

Design Profit ®
Page 65 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$46.52 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Plunger Piston 

Body, Hardened

$55.17 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 4

Plunger Piston 

Body

$55.17 Operation FM Solenoid Electroplate Process 0.3026 sec 1.8156 sec $0.00 $0.03 4

Plunger Piston 

Body

$55.17 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Plunger Piston 

Body

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

###### P.-P. Part FM Solenoid FM Solenoid Plunger Piston Body FM Solenoid 3.0000 sec 3.0000 sec - $0.03 4

Plunger Piston Shaft Plunger Piston 

Assy Body Shaft

###### Tool FM Solenoid Forging Press 500 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Piston 

Body Shaft

###### Part FM Solenoid FM Solenoid Plunger Piston Body FM Solenoid 0.0000 sec 0.0000 sec $0.01 $0.00 4

Plunger Piston Shaft, Material Plunger Piston 

Body Shaft Body Shaft, 

Material

- - - Raw Material Req 0.005 lbs - - - - - -

Actual + %

- - - Box Size 3.5mm D x 28.2mm L - - - - - -

- - - 1 hit based on rough - near net - - - - - -

shape

###### Material Mod. FM Solenoid Forge 500T 0.8500 sec 0.8500 sec $0.00 $0.03 4

Plunger Piston 

Body Shaft

$35.51 Tool FM Solenoid Press 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Piston 

Assy

$35.51 Fastening FM Solenoid Press to Depth 3.0000 sec 3.0000 sec $0.00 $0.03 4

Plunger Piston 

Assy

Design Profit ®
Page 66 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$35.51 Part FM Plunger Sub FM Solenoid Plunger Piston FM Solenoid 5.0000 sec 5.0000 sec $0.01 $0.05 4

Assy Spring Plunger Piston 

Spring

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$35.51 Subassembly FM Plunger Sub FM Solenoid Plunger Piston Body FM Solenoid 5.0000 sec 5.0000 sec - $0.05 4

Assy Assy Plunger Piston 

Body Assy

$35.51 Tool FM Solenoid First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Piston 

Body Assy

$20.90 P.-P. Part P.-P. Part FM Solenoid FM Solenoid FM Solenoid Plunger Piston Body FM Solenoid Plunger Piston Body FM Solenoid FM Solenoid 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec - $0.03 4

Plunger Piston Assy, Body Plunger Piston 

Body Assy Body Assy, Body

$20.90 Tool FM Solenoid Grinding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Piston 

Body Assy, Body

$46.52 P.-P. Part FM Solenoid FM Solenoid Plunger Piston Body FM Solenoid 3.0000 sec 3.0000 sec - $0.02 4

Plunger Piston Assy, Body Hardene Plunger Piston 

Body Assy, Body Body Assy, Body 

Hardene

$46.52 Tool FM Solenoid First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Piston 

Body Assy, Body 

Hardene

$20.90 P.-P. Part FM Solenoid FM Solenoid Plunger Piston Body FM Solenoid 3.0000 sec 3.0000 sec - $0.04 4

Plunger Piston Assy, Body Machine Plunger Piston 

Body Assy, Body Body Assy, Body 

Hardene Machine

Design Profit ®

Page 67 of #
Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$20.90 Tool FM Solenoid CNC Turning 2 Axis SL-10, 1.75" 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Piston bar

Body Assy, Body 

Machine

$20.90 Part FM Solenoid FM Solenoid Plunger Piston Body FM Solenoid 0.0000 sec 0.0000 sec $0.04 $0.00 4

Plunger Piston Assy, Body Materia Plunger Piston 

Body Assy, Body Body Assy, Body 

Machine Materia

- - - Includes Bar Feeder - - - - - -

- - - Bar stock weight .06 lbs. - - - - - -

- - - Box size of finished part - - - - - -

13.5Dmm x 21Lmm

$20.90 Operation FM Solenoid Bar Feeder Load & Clamp 3.0000 sec 3.0000 sec $0.00 $0.02 4

Plunger Piston 

Body Assy, Body 

Machine

- - - Machine ID - - - - - -

$20.90 Material Mod. FM Solenoid Drill Hole 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Body 

Machine

$20.90 Operation Operation FM Solenoid FM Solenoid Auto Tool Change Auto Tool Change 5.0000 sec 5.0000 sec 5.0000 sec 5.0000 sec $0.00 $0.03 4

Plunger Piston 

Body Assy, Body 

Machine

$20.90 Material Mod. FM Solenoid Bore Hole & Chamfer 2.0000 sec 2.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Body 

Machine

$20.90 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Plunger Piston 

Body Assy, Body 

Machine

$20.90 Material Mod. FM Solenoid Cut Small Groove 0.5000 sec 0.5000 sec $0.00 $0.00 24

Plunger Piston 

Body Assy, Body 

Machine

$20.90 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 20

Plunger Piston 

Body Assy, Body 

Machine
Design Profit

®

Page 68 of#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$20.90 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Plunger Piston 

Body Assy, Body 

Machine

- - - Machine OD - - - - - -

$20.90 Material Mod. FM Solenoid Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Body 

Machine

$20.90 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Body 

Machine

$20.90 Material Mod. FM Solenoid Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Body 

Machine

$20.90 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Body 

Machine

$20.90 Material Mod. FM Solenoid Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Body 

Machine

$20.90 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Body 

Machine

$20.90 Material Mod. FM Solenoid Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Body 

Machine

$20.90 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Body 

Machine

$20.90 Material Mod. FM Solenoid Chamfer OD sml 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Body 

Machine

Design Profit ®
Page 69 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$20.90 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Body 

Machine

$20.90 Material Mod. FM Solenoid Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Body 

Machine

$20.90 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Plunger Piston 

Body Assy, Body 

Machine

$20.90 Material Mod. FM Solenoid Cut to Length 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Body 

Machine

$20.90 Operation FM Solenoid Auto Eject Part 0.5000 sec 0.5000 sec $0.00 $0.00 4

Plunger Piston 

Body Assy, Body 

Machine

$20.90 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Plunger Piston 

Body Assy, Body 

Machine

$46.52 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 4

Plunger Piston 

Body Assy, Body 

Hardene

$46.52 Material Mod. FM Solenoid Induction Harden 2.0000 sec 2.0000 sec $0.00 $0.03 4

Plunger Piston 

Body Assy, Body 

Hardene

$46.52 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Plunger Piston 

Body Assy, Body 

Hardene

$20.90 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 4

Plunger Piston 

Body Assy, Body

$20.90 Material Mod. FM Solenoid Grind OD 0-1 Inch 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Body

Design Profit ®
Page 70 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$20.90 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Body

$20.90 Material Mod. FM Solenoid Grind to Length 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Body

$20.90 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Plunger Piston 

Body Assy, Body

$20.90 Material Mod. FM Solenoid Grind Chamfer 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Body

$20.90 Operation FM Solenoid Auto Eject Part 0.5000 sec 0.5000 sec $0.00 $0.00 4

Plunger Piston 

Body Assy, Body

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$46.52 P.-P. Part FM Solenoid FM Solenoid Plunger Piston Body FM Solenoid 3.0000 sec 3.0000 sec - $0.03 4

Plunger Piston Assy, Insert Plunger Piston 

Body Assy Body Assy, Insert

$46.52 Tool FM Solenoid First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Piston 

Body Assy, Insert

$28.18 P.-P. Part FM Solenoid FM Solenoid Plunger Piston Body FM Solenoid 3.0000 sec 3.0000 sec - $0.04 4

Plunger Piston Assy, Insert Machi Plunger Piston 

Body Assy, Insert Body Assy, Insert 

Machi

$28.18 Tool FM Solenoid CNC TL-15 2 Axis Twin Spindle 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Piston Lathe - Auto Load

Body Assy, Insert 

Machi

Design Profit ®

Page 71 of #
Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$28.18 Part FM Solenoid FM Solenoid Plunger Piston Body FM Solenoid 0.0000 sec 0.0000 sec $0.01 $0.00 4

Plunger Piston Assy, Insert Mater Plunger Piston 

Body Assy, Insert Body Assy, Insert 

Machi Mater

- - - Includes Bar Feeder - - - - - -

- - - Bar stock weight .005 lbs. - - - - - -

- - - Box size of finished part 6Dmm x - - - - - -

6Lmm

$28.18 Operation FM Solenoid Bar Feeder Load & Clamp 3.0000 sec 3.0000 sec $0.00 $0.02 4

Plunger Piston 

Body Assy, Insert 

Machi

- - - Machine ID - - - - - -

$28.18 Material Mod. FM Solenoid Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Insert 

Machi

$28.18 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 4

Plunger Piston 

Body Assy, Insert 

Machi

$28.18 Material Mod. Material Mod. FM Solenoid FM Solenoid Bore Hole 1-30mm Bore Hole 1-30mm 1.0000 sec 1.0000 sec 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Insert 

Machi

$28.18 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 4

Plunger Piston 

Body Assy, Insert 

Machi

- - - Machine OD - - - - - -

$28.18 Material Mod. FM Solenoid Machine Flat 1.0000 sec 1.0000 sec $0.00 $0.01 16

Plunger Piston 

Body Assy, Insert 

Machi

$28.18 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 12

Plunger Piston 

Body Assy, Insert 

Machi

$28.18 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 4

Plunger Piston 

Body Assy, Insert 

Machi

Design Profit ®
Page 72 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Engage Twin Spindle - - - - - -

$28.18 Material Mod. FM Solenoid Cut to Length 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Insert 

Machi

$28.18 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 4

Plunger Piston 

Body Assy, Insert 

Machi

$28.18 Material Mod. FM Solenoid Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Piston 

Body Assy, Insert 

Machi

$28.18 Operation FM Solenoid Auto Eject Part 0.5000 sec 0.5000 sec $0.00 $0.00 4

Plunger Piston 

Body Assy, Insert 

Machi

$28.18 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 4

Plunger Piston 

Body Assy, Insert 

Machi

$46.52 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 4

Plunger Piston 

Body Assy, Insert

$46.52 Material Mod. FM Solenoid Induction Harden 2.0000 sec 2.0000 sec $0.00 $0.03 4

Plunger Piston 

Body Assy, Insert

$46.52 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Plunger Piston 

Body Assy, Insert

$35.51 Tool FM Solenoid Press 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Piston 

Body Assy

$35.51 Fastening FM Solenoid Press to Depth 3.0000 sec 3.0000 sec $0.00 $0.03 4

Plunger Piston 

Body Assy

$35.51 Operation FM Plunger Sub Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 4

Assy

$35.51 Tool FM Plunger Sub Press 0.0000 sec 0.0000 sec $0.00 $0.00 4

Assy

$35.51 Fastening FM Plunger Sub Crimp Frame 1.0000 sec 1.0000 sec $0.00 $0.01 4

Assy

Design Profit ®
Page 73 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$35.51 Operation FM Plunger Sub Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 4

Assy

$35.51 Tool FM Plunger Sub Laser Welder 0.0000 sec 0.0000 sec $0.00 $0.00 4

Assy

$35.51 Operation FM Plunger Sub Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 4

Assy

$35.51 Fastening FM Plunger Sub Laser Weld 3.0000 sec 3.0000 sec $0.00 $0.03 4

Assy

$35.51 Operation FM Plunger Sub Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 4

Assy

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 74 of #

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$35.51 Subassembly FM Solenoid FM Solenoid Plunger Pin Assy FM Solenoid 5.0000 sec 5.0000 sec - $0.05 4

Plunger Assy Plunger Pin Assy

$35.51 Tool FM Solenoid First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Pin Assy

- - - Assemble Plunger Pin Assy - - - - - -

$55.17 P.-P. Part FM Solenoid FM Solenoid Plunger Pin FM Plunger Pin 3.0000 sec 3.0000 sec - $0.03 4

Plunger Pin Assy

$55.17 Tool FM Solenoid FM Solenoid Plating Equipment Plating Equipment 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Pin

$46.52 P.-P. Part FM Solenoid FM Solenoid Plunger Pin, FM Solenoid 3.0000 sec 3.0000 sec - $0.05 4

Plunger Pin Hardened Plunger Pin, 

Hardened

$46.52 Tool FM Solenoid First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Pin, 

Hardened

$20.90 P.-P. Part FM Solenoid FM Solenoid Plunger Pin, FM Solenoid 3.0000 sec 3.0000 sec - $0.04 4

Plunger Pin, Machined Plunger Pin, 

Hardened Machined

$20.90 Tool FM Solenoid CNC Turning 2 Axis SL-10, 1.75" 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Pin, bar

Machined

$83.31 P.-P. Part FM Solenoid FM Solenoid Plunger Pin, FM Solenoid 3.0000 sec 3.0000 sec - $0.02 4

Plunger Pin, Headed Plunger Pin, 

Machined Headed

$83.31 Tool FM Solenoid Forging Press 500 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Pin, 

Headed

Design Profit ®

Page 75 of #
Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$83.31 Part FM Solenoid FM Solenoid Plunger Pin, FM Solenoid 0.0000 sec 0.0000 sec $0.01 $0.00 4

Plunger Pin, Material Plunger Pin, 

Headed Material

- - - Bar stock weight .01 lbs. - - - - - -

- - - Box size of finished part 7Dmm x - - - - - -

10Lmm

- - - 2 hits based on rough - near net - - - - - -

shape

$83.31 Material Mod. FM Solenoid Forge 500T 0.8500 sec 0.8500 sec $0.00 $0.02 4

Plunger Pin, 

Headed

$83.31 Operation FM Solenoid Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.07 4

Plunger Pin, 

Headed

$83.31 Material Mod. FM Solenoid Forge 500T 0.8500 sec 0.8500 sec $0.00 $0.02 4

Plunger Pin, 

Headed

$83.31 Operation FM Solenoid Auto Eject Part 0.5000 sec 0.5000 sec $0.00 $0.01 4

Plunger Pin, 

Headed

$20.90 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 4

Plunger Pin, 

Machined

$20.90 Operation FM Solenoid Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.02 4

Plunger Pin, 

Machined

$20.90 Material Mod. FM Solenoid Drill Hole 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Pin, 

Machined

$20.90 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Plunger Pin, 

Machined

$20.90 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Pin, 

Machined

$20.90 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Plunger Pin, 

Machined

$20.90 Material Mod. FM Solenoid Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Pin, 

Machined

Design Profit ®
Page 76 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$20.90 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Plunger Pin, 

Machined

$20.90 Material Mod. FM Solenoid Chamfer Bolt Hole 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Pin, 

Machined

$20.90 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.03 4

Plunger Pin, 

Machined

$20.90 Material Mod. FM Solenoid Chamfer Bolt Hole 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Pin, 

Machined

$20.90 Operation FM Solenoid Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Pin, 

Machined

$20.90 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 4

Plunger Pin, 

Machined

$46.52 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 4

Plunger Pin, 

Hardened

$46.52 Material Mod. Material Mod. FM Solenoid FM Solenoid Induction Harden Induction Harden 2.0000 sec 2.0000 sec 2.0000 sec 2.0000 sec $0.00 $0.03 4

Plunger Pin, 

Hardened

$46.52 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Plunger Pin, 

Hardened

$55.17 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 4

Plunger Pin

$55.17 Operation FM Solenoid Electroplate Process 0.1816 sec 1.8156 sec $0.00 $0.03 4

Plunger Pin

$55.17 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Plunger Pin

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 77 of #
Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$55.17 P.-P. Part FM Solenoid FM Solenoid Plunger Pin Spacer FM Plunger Pin 5.0000 sec 5.0000 sec - $0.05 4

Plunger Pin Assy Spacer

$55.17 Tool FM Solenoid Plating Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Pin 

Spacer

$46.52 P.-P. Part FM Solenoid FM Solenoid Plunger Pin Spacer, FM Solenoid 3.0000 sec 3.0000 sec - $0.05 4

Plunger Pin Hardened Plunger Pin 

Spacer Spacer, Hardened

$46.52 Tool FM Solenoid First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Pin 

Spacer, Hardened

$28.18 P.-P. Part FM Solenoid FM Solenoid Plunger Pin Spacer, FM Solenoid 4.0000 sec 4.0000 sec - $0.05 4

Plunger Pin Machined Plunger Pin 

Spacer, Hardened Spacer, Machined

$28.18 Tool FM Solenoid CNC TL-15 2 Axis Twin Spindle 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Pin Lathe - Auto Load

Spacer, Machined

$28.18 Part FM Solenoid FM Solenoid Plunger Pin Spacer, FM Solenoid 0.0000 sec 0.0000 sec $0.01 $0.00 4

Plunger Pin Material Plunger Pin 

Spacer, Machined Spacer, Material

- - - Includes Bar Feeder - - - - - -

- - - Bar stock weight .005 lbs. - - - - - -

- - - Box size of finished part 10Dmm - - - - - -

x 2Lmm

$28.18 Operation FM Solenoid Feed Bar Stock 3.0000 sec 3.0000 sec $0.00 $0.02 4

Plunger Pin 

Spacer, Machined

$28.18 Material Mod. FM Solenoid Drill Hole 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Pin 

Spacer, Machined

$28.18 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 4

Plunger Pin 

Spacer, Machined

Design Profit ®

Page 78 of #
Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$28.18 Material Mod. FM Solenoid Bore Hole & Chamfer 2.0000 sec 2.0000 sec $0.00 $0.02 4

Plunger Pin 

Spacer, Machined

$28.18 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 4

Plunger Pin 

Spacer, Machined

$28.18 Material Mod. FM Solenoid Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Pin 

Spacer, Machined

$28.18 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 4

Plunger Pin 

Spacer, Machined

- - - Engage Twin Spindle - - - - - -

$28.18 Material Mod. FM Solenoid Cut to Length 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Pin 

Spacer, Machined

$28.18 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 4

Plunger Pin 

Spacer, Machined

$28.18 Material Mod. FM Solenoid Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 4

Plunger Pin 

Spacer, Machined

$28.18 Operation FM Solenoid Auto Eject Part 0.5000 sec 0.5000 sec $0.00 $0.00 4

Plunger Pin 

Spacer, Machined

$46.52 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 4

Plunger Pin 

Spacer, Hardened

$46.52 Material Mod. FM Solenoid Induction Harden 2.0000 sec 2.0000 sec $0.00 $0.03 4

Plunger Pin 

Spacer, Hardened

$46.52 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Plunger Pin 

Spacer, Hardened

$55.17 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 4

Plunger Pin 

Spacer

$55.17 Operation FM Solenoid Electroplate Process 0.3026 sec 1.8156 sec $0.00 $0.03 4

Plunger Pin 

Spacer

$55.17 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Plunger Pin 

Spacer

Design Profit ®
Page 79 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$43.52 P.-P. Part FM Solenoid FM Solenoid Plunger Pin Seal FM Plunger Pin 7.0000 sec 7.0000 sec - $0.07 4

Plunger Pin Assy Seal

$43.52 Tool FM Solenoid Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Pin Seal ton

$43.52 Part FM Solenoid FM Solenoid Plunger Pin Seal, FM Solenoid 0.0000 sec 0.6580 sec $0.01 $0.01 4

Plunger Pin Seal Material Plunger Pin Seal, 

Material

- - - Raw Material Req 0.0001 lbs - - - - - -

from Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 8mm L x 8mm W x - - - - - -

1mm H

$35.51 Part FM Solenoid FM Solenoid Plunger Spring, FM Plunger 4.0000 sec 4.0000 sec $0.01 $0.04 4

Plunger Assy Large Spring, Large

$35.51 Part FM Solenoid FM Solenoid Plunger Spring, FM Plunger 4.0000 sec 4.0000 sec $0.01 $0.04 4

Plunger Assy Small Spring, Small

- - - Press Sol. Plunger Assy into - - - - - -

Plunger Housing

$35.51 Multitouch FM Solenoid Load Housing Assy into Press Load Housing 3.0000 sec 3.0000 sec $0.00 $0.03 4

Plunger Assy Assy into Press

$35.51 Tool FM Solenoid Press 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Assy

$35.51 Fastening FM Solenoid Swedge Together 3.0000 sec 3.0000 sec $0.00 $0.03 4

Plunger Assy

$35.51 Operation FM Solenoid Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 4

Plunger Assy

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 80 of #

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$10.75 P.-P. Part FM Solenoid FM Solenoid Plunger Nose Piece FM Plunger Nose 3.0000 sec 3.0000 sec - $0.03 4

Plunger Assy Piece

$10.75 Tool FM Solenoid Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Nose DRY

Piece

$15.50 P.-P. Part FM Solenoid FM Solenoid Plunger Nose Piece, FM Solenoid 2.0000 sec 2.0000 sec - $0.01 4

Plunger Nose Stamped Plunger Nose 

Piece Piece, Stamped

$15.50 Tool FM Solenoid Stamping Press 0-60 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Nose 

Piece, Stamped

$15.50 Part FM Solenoid FM Solenoid Plunger Nose Piece, FM Solenoid 0.0000 sec 0.6000 sec $0.01 $0.00 4

Plunger Nose Material Plunger Nose 

Piece, Stamped Piece, Material

- - - Blank weight .003 lbs - - - - - -

- - - Press Size 25 Ton Progressive - - - - - -

- - - Part Size after stamping (9.05 - - - - - -

Dia. by 3.72 H)mm

$10.75 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 4

Plunger Nose 

Piece

$10.75 Operation FM Solenoid Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.01 4

Plunger Nose 

Piece

$10.75 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 4

Plunger Nose 

Piece

$35.51 Tool FM Solenoid Press 0.0000 sec 0.0000 sec $0.00 $0.00 4

Plunger Assy

Design Profit ®

Page 81 of #
Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$35.51 Fastening FM Solenoid Press to Depth 3.0000 sec 3.0000 sec $0.00 $0.03 4

Plunger Assy

$55.17 P.-P. Part FM Oil Control FM Solenoid Shell FM Solenoid Shell 3.0000 sec 3.0000 sec - $0.03 4

Solenoid

$55.17 Tool FM Solenoid Shell Plating Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 4

$42.68 P.-P. Part FM Solenoid Shell FM Solenoid Shell Machined FM Solenoid Shell 3.0000 sec 3.0000 sec - $0.05 4

Machined

$42.68 Tool FM Solenoid Shell CNC TL-15 4 Axis Twin Spindle 0.0000 sec 0.0000 sec $0.00 $0.00 4

Machined Lathe - Auto Load

$42.68 Part FM Solenoid Shell FM Solenoid Shell Material FM Solenoid Shell 0.0000 sec 0.0000 sec $0.09 $0.00 4

Machined Material

- - - Includes Bar Feeder - - - - - -

- - - Bar stock weight .15 lbs. - - - - - -

- - - Box size of finished part 29Dmm - - - - - -

x 26Lmm

$42.68 Operation FM Solenoid Shell Bar Feeder Load & Clamp 3.0000 sec 3.0000 sec $0.00 $0.04 4

Machined

$42.68 Operation FM Solenoid Shell Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.04 4

Machined

- - - Machine ID - - - - - -

$42.68 Material Mod. FM Solenoid Shell Turn I/D 30-60 mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Machined

$42.68 Operation FM Solenoid Shell CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Machined

$42.68 Material Mod. FM Solenoid Shell Turn I/D 30-60 mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Machined

$42.68 Operation FM Solenoid Shell CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Machined

$42.68 Material Mod. FM Solenoid Shell Turn I/D 30-60 mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Machined

$42.68 Operation FM Solenoid Shell Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 4

Machined

$42.68 Material Mod. FM Solenoid Shell Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 4

Machined

$42.68 Operation FM Solenoid Shell CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Machined

$42.68 Material Mod. FM Solenoid Shell Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 4

Machined

$42.68 Operation FM Solenoid Shell CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Machined

Design Profit ®
Page 82 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$42.68 Material Mod. FM Solenoid Shell Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 4

Machined

$42.68 Operation FM Solenoid Shell Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 4

Machined

$42.68 Material Mod. FM Solenoid Shell Cut to Length 2.0000 sec 2.0000 sec $0.00 $0.02 4

Machined

- - - Clamp Part with Twin Spindle - - - - - -

During Tool Change

$42.68 Operation FM Solenoid Shell Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 4

Machined

$42.68 Material Mod. FM Solenoid Shell Chamfer ID 1.0000 sec 1.0000 sec $0.00 $0.01 4

Machined

$42.68 Operation FM Solenoid Shell CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Machined

$42.68 Material Mod. FM Solenoid Shell Chamfer OD sml 1.0000 sec 1.0000 sec $0.00 $0.01 4

Machined

$42.68 Operation FM Solenoid Shell Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 4

Machined

$42.68 Operation FM Solenoid Shell Auto Eject Part 0.5000 sec 0.5000 sec $0.00 $0.01 4

Machined

$42.68 Operation FM Solenoid Shell Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.06 4

Machined

$55.17 Operation FM Solenoid Shell Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 4

$55.17 Operation FM Solenoid Shell Electroplate Process 0.3026 sec 1.8156 sec $0.00 $0.03 4

$55.17 Operation FM Solenoid Shell Unload Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

$35.51 Tool FM Oil Control Press 0.0000 sec 0.0000 sec $0.00 $0.00 4

Solenoid

- - - ID/OD Staking Operation - - - - - -

$35.51 Fastening FM Oil Control Gross Deform 5.0000 sec 5.0000 sec $0.00 $0.05 4

Solenoid

$35.51 Operation FM Oil Control CDI 1.0000 sec 1.0000 sec $0.00 $0.01 28

Solenoid

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®
Page 83 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$16.39 Subassembly FM Oil Control FM Electrical Assembly FM Electrical 3.0000 sec 3.0000 sec - $0.03 4

Solenoid Assembly

$16.39 Tool FM Electrical Injection Molding Machine 55-150 0.0000 sec 0.0000 sec $0.00 $0.00 4

Assembly ton

$42.90 Subassembly FM Electrical FM Bobbin Assembly FM Bobbin 3.0000 sec 3.0000 sec - $0.01 4

Assembly Assembly

$42.90 Tool FM Bobbin First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 4

Assembly

$0.00 P.-P. Part FM Bobbin FM Bobbin FM Bobbin 3.0000 sec 3.0000 sec $0.10 $0.04 4

Assembly

$42.90 Part FM Bobbin FM Bobbin Wire FM Bobbin Wire 3.0000 sec 3.0000 sec $0.12 $0.04 4

Assembly

$42.90 Operation FM Bobbin Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 4

Assembly

$42.90 Tool FM Bobbin Wire Winding Machine 0.0000 sec 0.0000 sec $0.00 $0.00 4

Assembly

$42.90 Operation FM Bobbin Wind Bobbin 15.0000 sec 15.0000 sec $0.00 $0.18 4

Assembly

$42.90 Operation Operation FM Bobbin FM Bobbin CDI 1.0000 sec 1.0000 sec 1.0000 sec 1.0000 sec $0.00 $0.01 4

Assembly

$42.90 Operation FM Bobbin Strip Wire Insulation 1.0000 sec 1.0000 sec $0.00 $0.01 8

Assembly

$42.90 Operation FM Bobbin CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Assembly

$83.31 P.-P. Part FM Bobbin FM Bobbin Terminals FM Bobbin 3.0000 sec 3.0000 sec $0.03 $0.04 8

Assembly Terminals

$42.90 Fastening FM Bobbin Crimp tabs 1.0000 sec 1.0000 sec $0.00 $0.01 8

Assembly

$42.90 Operation FM Bobbin CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Assembly

$42.90 Operation FM Bobbin Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 4

Assembly

$16.39 Operation FM Electrical Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 4

Assembly

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 84 of #
Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

$55.17 P.-P. Part FM Electrical FM Bobbin Spacer FM Bobbin Spacer 3.0000 sec 3.0000 sec - $0.01 4

Assembly

$55.17 Tool FM Bobbin Spacer Plating Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 4

$55.17 P.-P. Part FM Bobbin Spacer FM Bobbin Spacer, Peened FM Bobbin 3.0000 sec 3.0000 sec - $0.05 4

Spacer, Peened

$55.17 Tool FM Bobbin Deburing Equipment 0.0000 sec 0.0000 sec $0.00 $0.00 4

Spacer, Peened

$28.18 P.-P. Part FM Bobbin FM Bobbin Spacer, Machined FM Bobbin 3.0000 sec 3.0000 sec - $0.05 4

Spacer, Peened Spacer, Machined

$28.18 Tool FM Bobbin CNC TL-15 2 Axis Twin Spindle 0.0000 sec 0.0000 sec $0.00 $0.00 4

Spacer, Machined Lathe - Auto Load

$28.18 Part FM Bobbin FM Bobbin FM Bobbin Spacer, Material FM Bobbin Spacer, Material FM Bobbin FM Bobbin 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.03 $0.00 4

Spacer, Machined Spacer, Material

- - - Includes Bar Feeder - - - - - -

- - - Bar stock weight .07 lbs. - - - - - -

- - - Box size of finished part 25Dmm - - - - - -

x 8.5Lmm

$28.18 Operation FM Bobbin Feed Bar Stock 3.0000 sec 3.0000 sec $0.00 $0.02 4

Spacer, Machined

- - - Machine ID - - - - - -

$28.18 Material Mod. FM Bobbin Drill Hole 1.0000 sec 1.0000 sec $0.00 $0.01 4

Spacer, Machined

$28.18 Operation FM Bobbin Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 4

Spacer, Machined

$28.18 Material Mod. FM Bobbin Bore Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Spacer, Machined

$28.18 Operation FM Bobbin Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 4

Spacer, Machined

- - - Machine OD - - - - - -

Design Profit ®

Page 85 of #
Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$28.18 Material Mod. FM Bobbin Turn OD 30-60mm 2.0000 sec 2.0000 sec $0.00 $0.02 4

Spacer, Machined

$28.18 Operation FM Bobbin CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Spacer, Machined

$28.18 Material Mod. FM Bobbin Turn OD 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 4

Spacer, Machined

$28.18 Operation FM Bobbin CDI 1.0000 sec 1.0000 sec $0.00 $0.01 4

Spacer, Machined

$28.18 Material Mod. FM Bobbin Turn OD 30-60mm 2.0000 sec 2.0000 sec $0.00 $0.02 4

Spacer, Machined

$28.18 Operation FM Bobbin Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 4

Spacer, Machined

$28.18 Material Mod. FM Bobbin Machine Notch 1.0000 sec 1.0000 sec $0.00 $0.01 4

Spacer, Machined

$28.18 Operation FM Bobbin Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 4

Spacer, Machined

- - - Drill Blind Holes - - - - - -

$28.18 Material Mod. FM Bobbin Bore Small Pocket 0.5000 sec 0.5000 sec $0.00 $0.00 12

Spacer, Machined

$28.18 Operation FM Bobbin CDI 1.0000 sec 1.0000 sec $0.00 $0.01 8

Spacer, Machined

$28.18 Operation Operation FM Bobbin FM Bobbin Auto Tool Change Auto Tool Change 5.0000 sec 5.0000 sec 5.0000 sec 5.0000 sec $0.00 $0.04 4

Spacer, Machined

- - - Engage Twin Spindle - - - - - -

$28.18 Material Mod. FM Bobbin Cut to Length 1.0000 sec 1.0000 sec $0.00 $0.01 4

Spacer, Machined

$28.18 Operation FM Bobbin Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.04 4

Spacer, Machined

- - - Drill Blind Holes - - - - - -

$28.18 Material Mod. FM Bobbin Bore Small Pocket 0.5000 sec 0.5000 sec $0.00 $0.00 12

Spacer, Machined

$28.18 Operation FM Bobbin CDI 1.0000 sec 1.0000 sec $0.00 $0.01 8

Spacer, Machined

$28.18 Operation FM Bobbin Auto Eject Part 0.5000 sec 0.5000 sec $0.00 $0.00 4

Spacer, Machined

$55.17 Operation FM Bobbin Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 4

Spacer, Peened

$55.17 Tool FM Bobbin Sand Blast Equipment 4.0000 sec 4.0000 sec $0.00 $0.06 4

Spacer, Peened

$55.17 Material Mod. FM Bobbin Sand/Bead Blast 2.0000 sec 2.0000 sec $0.00 $0.03 4

Spacer, Peened

Design Profit ®
Page 86 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$55.17 Operation FM Bobbin Remove Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

Spacer, Peened

$55.17 Operation FM Bobbin Spacer Load Part 3.0000 sec 3.0000 sec $0.00 $0.05 4

$55.17 Operation FM Bobbin Spacer Electroplate Process 0.6052 sec 1.8156 sec $0.00 $0.03 4

$55.17 Operation FM Bobbin Spacer Remove Part 2.0000 sec 2.0000 sec $0.00 $0.03 4

$16.39 Operation FM Electrical Load Part 3.0000 sec 3.0000 sec $0.00 $0.01 4

Assembly

$16.39 Part FM Electrical FM Electrical Assembly, Mold FM Electrical 0.0000 sec 1.0550 sec $0.05 $0.00 4

Assembly Material Assembly, Mold 

Material

- - - Raw Material Req 0.030 lbs from - - - - - -

Cost Sheet

- - - 10 Cavity Mold - - - - - -

- - - Box Size 54mm L x 25mm W x - - - - - -

30mm H

$16.39 Operation FM Electrical Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 4

Assembly

$35.51 Tool FM Oil Control Press 0.0000 sec 0.0000 sec $0.00 $0.00 4

Solenoid

$35.51 Fastening FM Oil Control Press to Depth 3.0000 sec 3.0000 sec $0.00 $0.03 4

Solenoid

- - - Elect Test Elect Test - - - - - -

- - - Load/Unload Included - - - - - -

$25.00 Operation FM Oil Control Solenoid Flow Test 12.0000 sec 12.0000 sec $0.00 $0.08 4

Solenoid Asm

- - - Etch or Print Label - - - - - -

$25.00 Part FM Oil Control FM Label, Solenoid FM Label, 6.0000 sec 6.0000 sec $0.05 $0.04 4

Solenoid Asm Solenoid

$25.00 Fastening FM Oil Control Apply Label 3.0000 sec 3.0000 sec $0.00 $0.02 4

Solenoid Asm

$35.51 Tool FM Solenoid Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Housing Assy

$35.51 Fastening FM Solenoid Press to Depth 3.0000 sec 3.0000 sec $0.00 $0.03 4

Housing Assy

$35.51 Operation FM Solenoid Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Housing Assy

$35.51 Operation FM Solenoid Part Manipulation 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

- - - Install Oil Temp Sensor - - - - - -

Design Profit ®

Page 87 of #
Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$83.31 Subassembly FM Solenoid FM Oil Temp Sensor FM Oil Temp 7.0000 sec 7.0000 sec $2.49 $0.07 1

Housing Assy Sensor

$35.51 Tool FM Solenoid Hand Tool 3.0000 sec 3.0000 sec $0.00 $0.03 1

Housing Assy

$35.51 Fastening FM Solenoid Manual Screw 7.0000 sec 7.0000 sec $0.00 $0.07 1

Housing Assy

- - - Install Oil Feed O-Ring - - - - - -

$35.51 Part FM Solenoid FM Primary Oil Feed O-Ring, FM Primary Oil 4.0000 sec 4.0000 sec $0.04 $0.04 1

Housing Assy Center Hsg. Feed O-Ring, 

Center Hsg.

$35.51 Fastening FM Solenoid Push In Place 2.0000 sec 2.0000 sec $0.00 $0.02 1

Housing Assy

- - - Air/Oil/Elect Test - - - - - -

- - - Load/Unload Included - - - - - -

- - - Etch Data Label(s) - - - - - -

$50.00 Operation FM Solenoid Multi Air Function Test 30.0000 sec 30.0000 sec $0.00 $0.42 1

Housing Assy, 

Tested

$35.51 Part FM Multi Air FM Solenoid Housing Bolt FM Solenoid 4.0000 sec 4.0000 sec $0.06 $0.04 9

System Housing Bolt

$35.51 Tool FM Multi Air Power Tool 4.0000 sec 4.0000 sec $0.00 $0.04 1

System

$35.51 Fastening FM Multi Air Power Screw 4.0000 sec 4.0000 sec $0.00 $0.04 9

System

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 88 of #
Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 89 of #

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 90 of #

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 91 of #

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 92 of #

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 93 of #

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 94 of #

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Install Solenoid Housing Cover - - - - - -

Plate Assembly

$35.51 Subassembly FM Multi Air FM Solenoid Cover Plate Assy FM Solenoid 3.0000 sec 3.0000 sec - $0.03 1

System Cover Plate Assy

$35.51 Tool FM Solenoid First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Plate Assy

$35.51 P.-P. Part FM Solenoid FM Solenoid Cover Base Plate FM Solenoid 3.0000 sec 3.0000 sec - $0.03 1

Cover Plate Assy Cover Base Plate

$35.51 Tool FM Solenoid First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Base Plate

$20.81 P.-P. Part FM Solenoid FM Solenoid Cover Base Plate, FM Solenoid 3.0000 sec 3.0000 sec - $0.03 1

Cover Base Plate Washed Cover Base Plate, 

Washed

$20.81 Tool FM Solenoid Washer Duo 400 Wash Rinse & 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Base Plate, DRY

Washed

$35.42 P.-P. Part FM Solenoid FM Solenoid Cover Base Plate, FM Solenoid 3.0000 sec 3.0000 sec - $0.02 1

Cover Base Plate, Machined Cover Base Plate, 

Washed Machined

$35.42 Tool FM Solenoid EC-400-ML Horizontal CNC 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Base Plate, Machine

Machined

$42.91 P.-P. Part FM Solenoid FM Solenoid Cover Base Plate, FM Solenoid 3.0000 sec 3.0000 sec - $0.03 1

Cover Base Plate, Stamped Cover Base Plate, 

Machined Stamped

$42.91 Tool FM Solenoid Stamping Press 200-400 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Base Plate, 

Stamped

$42.91 Part FM Solenoid FM Solenoid Cover Base Plate, FM Solenoid 0.0000 sec 1.8000 sec $1.33 $0.02 1

Cover Base Plate, Material Cover Base Plate, 

Stamped Material

- - - Blank weight 1.212 lbs - - - - - -

Design Profit ®
Page 95 of

#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

- - - Press Size 300 Ton Progressive - - - - - -

- - - Part Size after stamping (335 L - - - - - -

by 86 W by 29 H)mm

$35.42 Operation FM Solenoid Pallet to workspace/tool to pallet 1.0000 sec 1.0000 sec $0.00 $0.01 1

Cover Base Plate, 

Machined

$35.42 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Cover Base Plate, 

Machined

$35.42 Operation FM Solenoid Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Cover Base Plate, 

Machined

$35.42 Material Mod. FM Solenoid Drill & Chamfer Hole 1-30mm 1.0000 sec 1.0000 sec $0.00 $0.01 9

Cover Base Plate, 

Machined

$35.42 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 8

Cover Base Plate, 

Machined

$35.42 Operation FM Solenoid Auto Tool Change 5.0000 sec 5.0000 sec $0.00 $0.05 1

Cover Base Plate, 

Machined

$35.42 Material Mod. Material Mod. FM Solenoid FM Solenoid Drill Hole 1-30mm Drill Hole 1-30mm 1.0000 sec 1.0000 sec 1.0000 sec 1.0000 sec $0.00 $0.01 8

Cover Base Plate, 

Machined

$35.42 Operation FM Solenoid CDI 1.0000 sec 1.0000 sec $0.00 $0.01 7

Cover Base Plate, 

Machined

$35.42 Operation FM Solenoid Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Cover Base Plate, 

Machined

$35.42 Operation FM Solenoid Tool to home/pallet to operator 1.0000 sec 1.0000 sec $0.00 $0.01 1

Cover Base Plate, 

Machined

$35.42 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Cover Base Plate, 

Machined

$20.81 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 1

Cover Base Plate, 

Washed

$20.81 Operation FM Solenoid Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.03 1

Cover Base Plate, 

Washed
Design Profit

®

Page 96 of#

Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$20.81 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Cover Base Plate, 

Washed

$35.51 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Cover Base Plate

$35.51 Operation FM Solenoid Clamp Part 3.0000 sec 3.0000 sec $0.00 $0.03 1

Cover Base Plate

$35.51 Tool FM Solenoid Fluid Dispenser 4.0000 sec 4.0000 sec $0.00 $0.04 1

Cover Base Plate

$35.51 Part FM Solenoid FM Solenoid Cover Base Plate FM Solenoid 2.0000 sec 30.0000 sec $0.03 $0.30 1

Cover Base Plate Gasket Material Cover Base Plate 

Gasket Material

$35.51 Operation FM Solenoid Unclamp Part 1.0000 sec 1.0000 sec $0.00 $0.01 1

Cover Base Plate

$35.51 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Cover Base Plate

$0.00 P.-P. Part FM Solenoid FM Solenoid Cover Check Valve FM Solenoid 3.0000 sec 3.0000 sec $0.12 $0.03 1

Cover Plate Assy Cover Check 

Valve

$35.51 Tool FM Solenoid Press 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Plate Assy

$35.51 Fastening Fastening FM Solenoid FM Solenoid Press to Depth Press to Depth 3.0000 sec 3.0000 sec 3.0000 sec 3.0000 sec $0.00 $0.03 1

Cover Plate Assy

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

- - - Space for Printing - - - - - -

Design Profit ®

Page 97 of #
Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$42.91 P.-P. Part FM Solenoid FM Solenoid Cover Plate Gasket FM Solenoid 4.0000 sec 4.0000 sec - $0.04 1

Cover Plate Assy Cover Plate 

Gasket

$42.91 Tool FM Solenoid Stamping Press 200-400 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Plate 

Gasket

$42.91 Part FM Solenoid FM Solenoid Cover Plate Gasket FM Solenoid 0.0000 sec 1.8000 sec $0.07 $0.02 1

Cover Plate Material Cover Plate 

Gasket Gasket Material

- - - Blank weight .098 lbs - - - - - -

- - - Press Size 300 Ton Progressive - - - - - -

- - - Part Size after stamping (335 L - - - - - -

by 55 W by .5 H)mm

- - - Space for Printing - - - - - -

$42.90 P.-P. Part FM Solenoid FM Solenoid Cover Plate FM Solenoid 3.0000 sec 3.0000 sec - $0.03 1

Cover Plate Assy Cover Plate1

$42.90 Tool FM Solenoid First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Plate

$20.81 P.-P. Part FM Solenoid FM Solenoid Cover Plate, FM Solenoid 3.0000 sec 3.0000 sec - $0.04 1

Cover Plate Washed Cover Plate, 

Washed

$20.81 Tool FM Solenoid FM Solenoid Washer Duo 400 W sher Duo 400 Wash Rinse & ash Rinse & 0.0000 sec 0.0000 sec 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Plate, DRY

Washed

$42.91 P.-P. Part FM Solenoid FM Solenoid Cover Plate FM Solenoid 3.0000 sec 3.0000 sec - $0.02 1

Cover Plate, Stamped Cover Plate 

Washed Stamped

$42.91 Tool FM Solenoid Stamping Press 200-400 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Plate 

Stamped

$42.91 Part FM Solenoid FM Solenoid Cover Plate Material FM Solenoid 0.0000 sec 1.7000 sec $0.16 $0.02 1

Cover Plate Cover Plate 

Stamped Material

- - - Blank weight .338 lbs - - - - - -

- - - Press Size 200 Ton Progressive - - - - - -

- - - Part Size after stamping 335 L by - - - - - -

56 W by 12 H)mm

$20.81 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.02 1

Cover Plate, 

Washed

Design Profit ®

Page 98 of #
Copyright 2010 © Design Profit, Inc.
FM Multi Air System

Labor Type Parent Name

Symbol Name

Number Munro Score Actual Time Piece Cost Total Labor Qty

Rate Cost (Total)

$20.81 Operation FM Solenoid Wash Part Medium 5.0000 sec 5.0000 sec $0.00 $0.03 1

Cover Plate, 

Washed

$20.81 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.01 1

Cover Plate, 

Washed

$42.90 Operation FM Solenoid Load Part 3.0000 sec 3.0000 sec $0.00 $0.04 1

Cover Plate

$42.90 Tool FM Solenoid Laser Symbolizer 0.0000 sec 0.0000 sec $0.00 $0.00 1

Cover Plate

$42.90 Material Mod. FM Solenoid Laser Etch 2.0000 sec 2.0000 sec $0.00 $0.02 1

Cover Plate

$42.90 Operation FM Solenoid Unload Part 2.0000 sec 2.0000 sec $0.00 $0.02 1

Cover Plate

$35.51 Tool FM Solenoid Stake Tool 2.0000 sec 2.0000 sec $0.00 $0.02 1

Cover Plate Assy

$35.51 Fastening FM Solenoid Stake in Place 3.0000 sec 3.0000 sec $0.00 $0.03 2

Cover Plate Assy

$35.51 Part FM Multi Air FM Solenoid Cover Plate Bolt FM Solenoid 4.0000 sec 4.0000 sec $0.03 $0.04 18

System Cover Plate Bolt

$35.51 Tool FM Multi Air Power Tool 4.0000 sec 4.0000 sec $0.00 $0.04 1

System

$35.51 Fastening FM Multi Air Power Screw 4.0000 sec 4.0000 sec $0.00 $0.04 18

System

Report Totals Count: ##

4,727

Design Profit ®

Page 99 of #
Copyright 2010 © Design Profit, Inc.
Piece Co

(Total)

$0.00

-

$0.00

$0.09

-

-

-

-

-

$0.00

-

$0.00

-

$0.00

-

$0.00

Piece Co

(Total)

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

-

$8.18

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

-

-

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

Piece Co

(Total)

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

-

$0.00

Piece Co

(Total)

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

Piece Co

(Total)

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

-

$0.00

$0.00

-

$0.00

$0.00

-

$0.00

Piece Co

(Total)

$0.00

$0.00

-

$0.00

$0.00

-

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

Piece Co

(Total)

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

$0.00

$0.00

Piece Co

(Total)

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

Piece Co

(Total)

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

-

Piece Co

(Total)

$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

Piece Co

(Total)

-

$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

Piece Co

(Total)

$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

Piece Co

(Total)

$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

Piece Co

(Total)

$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

Piece Co

(Total)

$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

Piece Co

(Total)

$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

Piece Co

(Total)

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

-

$0.00

Piece Co

(Total)

$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

Piece Co

(Total)

$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

Piece Co

(Total)

-

-

-

$0.00

$0.00

$0.00

-

$0.40

$0.00

$0.00

$0.00

$0.00

-

$0.12

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.08

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.04

$0.02

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.04

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

$0.00

$0.00

-

$0.00

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

$0.00

-

$0.00

-

$0.00

-
Piece Co

(Total)

$0.00

-

$0.00

$0.06

-

-

-

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

$0.00

$0.00

Piece Co

(Total)

$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

-

$0.50

Piece Co

(Total)

-

-

-

$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

Piece Co

(Total)

$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

-

Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

$0.00
Piece Co

(Total)

-

$0.00

-

$0.00

-

$0.00

-

$0.00

$0.30

-

-

-

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

-

Piece Co

(Total)

$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

Piece Co

(Total)

$0.00

$0.00

$0.00

-

$0.00

-

$0.00

$0.03

-

-

-

$0.00

$0.00

$0.00

$0.08

$0.00

$0.00

$0.92

$8.00

$0.00

$0.00

-

Piece Co

(Total)

$0.00

$0.16

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

$0.00

$0.04

-

-

-

$0.00

Piece Co

(Total)

$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

$0.28

Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

Piece Co

(Total)

$0.00

$0.04

-

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

$0.00

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.04

$0.00

$0.00

-

$0.96

-

-

$0.00

-

-

$0.00

-

$0.00

Piece Co

(Total)

-

$0.00

$0.08

$0.00

-

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.16

$0.00

$0.00

-

-

-

-

-

-

Piece Co

(Total)

-

-

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

$0.00

Piece Co

(Total)

$0.15

$0.00

-

-

-

$0.00

-

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

$0.00

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Co

(Total)

-

$0.00

-

$0.00

$0.08

-

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.08

Piece Co

(Total)

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

$0.89

-

-

$0.00

-

$0.00

Piece Co

(Total)

$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

Piece Co

(Total)

$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

Piece Co

(Total)

$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

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

-

-

Piece Co

(Total)

$0.00

-

$0.00

-

$0.00

-

$0.00

-

$0.00

$0.05

$0.00

-

-

-

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

-

$0.32

$0.00

$0.32

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

-

-

-

-

-

-

-

Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

-

$0.00

-

$0.00

-

$0.00

-

-

$0.00

-

$0.00

-

$0.00

Piece Co

(Total)

$0.59

-

-

-

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Co

(Total)

$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

Piece Co

(Total)

$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

Piece Co

(Total)

$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

Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

$0.00

-

$0.00

-
Piece Co

(Total)

$0.00

-

$0.00

$0.04

-

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.00

Piece Co

(Total)

$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

-

-

-

Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

$0.00

-

$0.00

-

$0.00

$0.02

-

-

-

$0.00

$0.00

$0.00

-

Piece Co

(Total)

$0.00

$0.08

-

-

-

-

-

-

-

-

-

$0.00

-

$0.00

-

$0.00

-

$0.00

Piece Co

(Total)

-

$0.00

$0.05

-

-

-

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

$0.00

$0.03

-

-

-

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.04

-

-

-

-

-

-

-

-

-

-

-

-

$0.00

-

$0.00

-

$0.00

-

Piece Co

(Total)

$0.00

$0.15

-

-

-

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

-

-

-

-

-

-

-

$0.00

-

$0.00

Piece Co

(Total)

$0.04

-

-

-

$0.00

-

$0.00

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

Piece Co

(Total)

-

$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

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

$0.00

-

-

$0.00

-

$0.00

-

$0.00

-

$0.00

Piece Co

(Total)

$0.04

-

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

-

-

Piece Co

(Total)

-

-

-

-

-

-

-

-

-

$0.00

-

$0.00

-

$0.00

$0.04

-

-

-

$0.00

$0.00

$0.00

Piece Co

(Total)

$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

Piece Co

(Total)

-

-

-

-

-

-

$0.00

$0.04

-

-

-

$0.04

$0.04

-

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-

-

-
Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

$0.00

-

$0.00

$0.04

-

-

-

$0.00

$0.00

$0.00

$0.00

Piece Co

(Total)

$0.00

-

$0.00

-

$0.00

$0.37

-

-

-

$0.00

$0.00

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

Piece Co

(Total)

$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

-

-

-

-

-

-

-

Piece Co

(Total)

-

-

-

-

$0.00

-

$0.00

$0.40

$0.49

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.24

$0.00

$0.00

$0.00

$0.00

-

-

-

Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

$0.00

-

$0.00

-

$0.00

$0.13

-

-

-

$0.00

-

$0.00

$0.00

$0.00

$0.00

-

Piece Co

(Total)

$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

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.19

-

-

-

$0.00

$0.00

$0.00

-

-

$0.00

-

$0.20

$0.00

$0.00

$0.00

$0.00

$0.00

-

Piece Co

(Total)

$2.49

$0.00

$0.00

-

$0.04

$0.00

-

-

-

$0.00

$0.54

$0.00

$0.00

-

-

-

-

-

-

-

-

-

-

-

-

-

-

Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-
Piece Co

(Total)

-

-

-

-

-

-

-

-

-

-

$0.00

-

$0.00

-

$0.00

-

$0.00

-

$0.00

$1.33

-

Piece Co

(Total)

-

-

$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

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.03

$0.00

$0.00

$0.12

$0.00

$0.00

-

-

-

-

-

-

-

-

-

-

-

-

-

-

Piece Co

(Total)

-

$0.00

$0.07

-

-

-

-

-

$0.00

-

$0.00

-

$0.00

$0.16

-

-

-

$0.00

Piece Co

(Total)

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.54

$0.00

$0.00

$31.12

Page:1 of 3 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

Material Labor Burden End Item 

Scrap SG&A Profit ED&T-R&D Material Labor Burden

07 Valvetrain Subsystem

1 00 Assembly of Valvetrain Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - #REF! #REF! #REF!

2 01 Inlet Valves $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - #REF! #REF! #REF!

3 02 Outlet Valves $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - #REF! #REF! #REF!

4 03 Valve Springs $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - #REF! #REF! #REF!

5 04 Spring Retainers, Cotters, Spring Seats $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - #REF! #REF! #REF!

SYSTEM & SUBSYSTEM DESCRIPTION NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Fiat Motors 1.4L Turbo, I4, 135hp, 206N.m Torque Gas Powered Engine

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

I

(x1000) tem

Subsystem

Markup Net Manufacturing 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

System 

ED&T/R&D

(x1000)

Sub-Subsystem Description Investment

(X1000)

Technology Level: Variable Inlet & Exhaust Valve Timing (Solenoid Controlled)

Vehicle Class: Sub-Compact Size Passenger Vehicle, 3-4 Passengers

Study Case#: N0200 (N=New, 02=Multi-Air, 00 =Subcompact Vehicle Class)

6 05 Valve Actuation Elements: Rockers, Finger Followers, Hydraulic Lash Adjusters,... $ 46.18 $ 53.67 $ 85.79 $ 185.64 $ 1.57 $ 21.96 $ 19.14 $ 5.74 $ 48.41 $ 0.10 $ 234.14 $ - $ - $ - #REF! #REF! #REF!

7 06 Camshafts $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - #REF! #REF! #REF!

8 08 Camshaft Phaser and/or Cam Sprockets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - #REF! #REF! #REF!

9 65 Adapters $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - #REF! #REF! #REF!

10 70 Pipes, Hoses, Ducting $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - #REF! #REF! #REF!

11 75 Brackets $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - #REF! #REF! #REF!

12 80 Boltings $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - #REF! #REF! #REF!

13 85 Sealing Elements $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - #REF! #REF! #REF!

14 90 Bearings Elements Misc $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - #REF! #REF! #REF!

15 95 Vehicle Body Interface (ie Brackets, Wiring, etc) $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - #REF! #REF! #REF!

16 99 Miscellaneous $ 24.27 $ 0.68 $ 2.32 $ 27.27 $ 0.14 $ 1.77 $ 1.64 $ 0.68 $ 4.23 $ - $ 31.50 $ - $ - $ - #REF! #REF! #REF!

SUBSYSTEM ROLL-UP $ 70.45 $ 54.36 $ 88.10 $ 212.91 $ 1.71 $ 23.73 $ 20.78 $ 6.42 $ 52.64 $ 0.10 $ 265.64 $ - $ - $ - #REF! #REF! #REF!

09000064810e7549.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:2 of 3 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

07 Valvetrain Subsystem

1 00

2 01

3 02

4 03

5 04

Item

Subsystem

End Item 

Scrap SG&A Profit ED&T-R&D Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

System 

ED&T/R&D

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

BASE TECHNOLOGY GENERAL PART INFORMATION:

??? INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

6 05

7 06

8 08

9 65

10 70

11 75

12 80

13 85

14 90

15 95

16 99

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

#REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF! #REF!

09000064810e7549.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Author: G. Kolwich

(248)373-6000 Ext. 2411
Page:3 of 3 COST MODEL ANALYSIS TEMPLATE

Light-Duty Technology Cost Study

EP-C-07-069 WA1-3

Printed: 8/23/2012

DRAFT

07 Valvetrain Subsystem

1 00

2 01

3 02

4 03

5 04

Item

Subsystem

#REF! #REF!

#REF! #REF!

#REF! #REF!

#REF! #REF!

#REF! #REF!

Tooling 

(x1000)

Investment 

(X1000)

6 05

7 06

8 08

9 65

10 70

11 75

12 80

13 85

14 90

15 95

16 99

#REF! #REF!

#REF! #REF!

#REF! #REF!

#REF! #REF!

#REF! #REF!

#REF! #REF!

#REF! #REF!

#REF! #REF!

#REF! #REF!

#REF! #REF!

#REF! #REF!

#REF! #REF!

09000064810e7549.xls

EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL

Author: G. Kolwich

(248)373-6000 Ext. 2411