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 Material Labor Burden

000000 Vehicle

1 01 Engine System $ 506.26 $ 145.72 $ 518.82 $ 1,170.80 $ 17.66 $ 55.10 $ 54.28 $ 19.29 $ 146.33 $ 3.80 $ 1,320.94 $ - $ - $ - $ 715.90 $ 206.07 $ 733.66

2 02 Transmission System $ 1,010.34 $ 331.85 $ 532.55 $ 1,874.73 $ 17.46 $ 127.56 $ 132.73 $ 57.79 $ 335.54 $ 6.16 $ 2,216.43 $ - $ - $ - $ 492.10 $ 140.17 $ 274.33

3 03 Body System $ 32.76 $ 18.10 $ 13.06 $ 63.92 $ 0.59 $ 7.64 $ 7.11 $ 2.27 $ 17.62 $ 0.17 $ 81.71 $ - $ - $ - $ 24.88 $ 18.04 $ 14.89

4 04 Suspension System $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

5 05 Driveline System $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Item

System 

ED&T/R&D

(x1000)

System Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Manufacturing 

Investment

(X1000)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

6 06 Brake System $ 113.54 $ 51.26 $ 67.54 $ 232.34 $ 1.88 $ 20.60 $ 17.75 $ 5.98 $ 46.21 $ 0.51 $ 279.06 $ - $ - $ - $ 14.08 $ 9.91 $ 12.51

7 07 Frame and Mounting System $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 08 Clutch System $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 09 Exhuast System (Included In Engine Downsizing Credit) $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 10 Fuel System $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 11 Steering System $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 12 Climate System $ 176.13 $ 29.38 $ 48.59 $ 254.11 $ 2.12 $ 17.46 $ 16.48 $ 6.89 $ 42.95 $ 0.15 $ 297.21 $ - $ - $ - $ 24.10 $ 19.18 $ 25.92

13 13 Information and Gauge System $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 14 Electrical Power Supply System $ 1,383.60 $ 191.52 $ 315.70 $ 1,890.81 $ 14.22 $ 127.76 $ 136.21 $ 64.40 $ 342.59 $ 3.56 $ 2,236.96 $ - $ - $ - 0 $ 32.50 $ 11.05 $ 27.95

15 15 Entertainment System $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

16 16 Vacuum System $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

17 17 Lighting System $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

18 18 Electrical Distribution and Control System $ 127.00 $ 32.43 $ 16.16 $ 175.58 $ 0.81 $ 10.64 $ 9.75 $ 4.03 $ 25.23 $ 0.68 $ 201.50 $ - $ - $ - 0 $ - $ - $ -

19 19 Electrical Feature System $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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 Material Labor Burden

Item

System 

ED&T/R&D

(x1000)

System Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Manufacturing 

Investment

(X1000)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

20 20 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

VEHICLE ROLL-UP $ 3,349.62 $ 800.27 $ 1,512.41 $ 5,662.30 $ 54.75 $ 366.75 $ 374.32 $ 160.66 $ 956.47 $ 15.04 $ 6,633.81 $ - $ - $ - $ 1,303.57 $ 404.42 $ 1,089.25

09000064810ec171.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

000000 Vehicle

1 01

2 02

3 03

4 04

5 05

Item

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

$ 1,655.63 $ 24.98 $ 77.91 $ 76.76 $ 27.28 $ 206.93 $ 5.38 $ 1,867.94 $ - $ - $ - $ (209.64) $ (60.35) $ (214.84) $ (484.83) $ (7.32) $ (22.81) $ (22.48) $ (7.99) $ (60.60) $ (1.58) $ (547.00) $ -

$ 906.60 $ 6.51 $ 59.17 $ 55.27 $ 15.12 $ 136.07 $ 4.49 $ 1,047.17 $ - $ - $ - $ 518.23 $ 191.68 $ 258.22 $ 968.13 $ 10.95 $ 68.39 $ 77.46 $ 42.68 $ 199.47 $ 1.66 $ 1,169.27 $ -

$ 57.81 $ 0.60 $ 7.67 $ 7.13 $ 2.19 $ 17.59 $ - $ 75.39 $ - $ - $ - $ 7.87 $ 0.07 $ (1.82) $ 6.12 $ (0.00) $ (0.02) $ (0.02) $ 0.08 $ 0.03 $ 0.17 $ 6.31 $ -

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

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

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

6 06

7 07

8 08

9 09

10 10

11 11

12 12

13 13

14 14

15 15

16 16

17 17

18 18

$ 36.50 $ 0.18 $ 2.45 $ 2.27 $ 0.87 $ 5.76 $ 0.12 $ 42.39 $ - $ - $ - $ 99.45 $ 41.35 $ 55.03 $ 195.83 $ 1.70 $ 18.14 $ 15.48 $ 5.12 $ 40.45 $ 0.40 $ 236.68 $ -

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

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

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

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

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

$ 69.20 $ 0.58 $ 6.52 $ 5.56 $ 1.89 $ 14.56 $ - $ 83.75 $ - $ - $ - $ 152.04 $ 10.21 $ 22.67 $ 184.91 $ 1.53 $ 10.94 $ 10.93 $ 5.00 $ 28.39 $ 0.15 $ 213.46 $ -

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

$ 71.50 $ 0.34 $ 4.42 $ 4.08 $ 1.70 $ 10.54 $ 0.13 $ 82.17 $ - $ - $ - $ 1,351.10 $ 180.47 $ 287.75 $ 1,819.31 $ 13.88 $ 123.34 $ 132.13 $ 62.70 $ 332.05 $ 3.44 $ 2,154.80 $ -

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

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

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 127.00 $ 32.43 $ 16.16 $ 175.58 $ 0.81 $ 10.64 $ 9.75 $ 4.03 $ 25.23 $ 0.68 $ 201.50 $ -

19 19 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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

Item

SYSTEM & SUBSYSTEM DESCRIPTION

20 20

End Item 

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

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

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

$ 2,797.24 $ 33.19 $ 158.14 $ 151.07 $ 49.05 $ 391.45 $ 10.11 $ 3,198.80 $ - $ - $ - $ 2,046.05 $ 395.85 $ 423.16 $ 2,865.06 $ 21.56 $ 208.61 $ 223.25 $ 111.61 $ 565.02 $ 4.93 $ 3,435.01 $ -

09000064810ec171.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

000000 Vehicle

1 01

2 02

3 03

4 04

5 05

Item

SYSTEM & SUBSYSTEM DESCRIPTION

Sub-Compact Vehicle Segment 

(e.g Ford Fiesta)

Small/Compact Vehicle Segment 

(e.g Ford Focus)

Large Size Vehicle Segment 

(e.g Ford Flex)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

$ - $ - $ (193.35) $ (87.53) $ (131.30)

$ - $ - $ 1,008.12 $ 1,026.02 $ 1,173.34

$ - $ - $ 6.31 $ 6.31 $ 6.31

$ - $ - $ - $ - $ -

$ - $ - $ - $ - $ -

Investment(X1

000)

Tooling 

(x1000)

POWER-SPLIT SCALING ANALYSIS

6 06

7 07

8 08

9 09

10 10

11 11

12 12

13 13

14 14

15 15

16 16

17 17

18 18

$ - $ - $ 229.83 $ 232.20 $ 241.96

$ - $ - $ - $ - $ -

$ - $ - $ - $ - $ -

$ - $ - $ - $ - $ -

$ - $ - $ - $ - $ -

$ - $ - $ - $ - $ -

$ - $ - $ 204.33 $ 207.89 $ 230.48

$ - $ -

$ - $ - $ 1,406.23 $ 1,594.08 $ 2,463.98

$ - $ -

$ - $ -

$ - $ -

$ - $ - $ 191.45 $ 196.19 $ 203.75

19 19 $ - $ -

09000064810ec171.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

Item

SYSTEM & SUBSYSTEM DESCRIPTION

20 20

Sub-Compact Vehicle Segment 

(e.g Ford Fiesta)

Small/Compact Vehicle Segment 

(e.g Ford Focus)

Large Size Vehicle Segment 

(e.g Ford Flex)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Investment(X1

000)

Tooling 

(x1000)

POWER-SPLIT SCALING ANALYSIS

$ - $ -

$ - $ - $ 2,852.92 $ 3,175.16 $ 4,188.52

0.830540803 0.924352192 1.219363375

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
Appendix

A 000000 Vehicle

A.1 010000 Engine System

A.2 020000 Transmission System

A.2.1 020200 Case Subsystem

A.2.2 020300 Gear Train Subsystem

A.2.3 020400 Internal Clutch Subsystem

A.2.4 020500 Launch Clutch Subsystem

A.2.5 020600 Oil Pump and Filter Subsystem

A.2.6 020700 Mechanical Controls Subsystem

A.2.7 02'0800A Electrical Controls Subsystem

A.2.8 020800B Transmission Control Module (Est. $150)

A.2.9 020900 Parking Mechanism Subsystem

A.2.10 021100 Electric Motor & Controls Subsystem

A.2.11 021200 Transmission Cooling System

A.2.12 021300 OE Transmission Assembly (broke out for eCVT only, included in subsystem roll-ups in base analysis) 

A.3 030000 Body System

A.3.1 030300 Body Closures Subsystem

A.3.2 030500 Interior Trim and Ornamentation Subsystem

A.3.3 030600 Sound and Heat Control Subsystem (Body)

A.3.4 031000 Seating Subsystem

A.4 060000 Brake System

A.4.1 060600 Brake Actuation Subsystem

A.4.2 060700 Power Brake Subsystem (for Hydraulic)

A.4.3 060900 Brake Controls Subsystem

A.5 120000 Climate Control System

A.5.1 120200 Heating Defrosting Subsystem

A.5.2 120300 Refrigeration/Air Conditioning Subsystem

A.6 140000 Electrical Power Supply System

A.6.1 140100 Service Battery Subsystem

A.6.2 140200 Generator/Alternator and Regulator Subsystem

A.6.3 140300 High Voltage Traction Battery Subsystem

A.6.4 140500 Voltage Converter / Inverter Subsystem

A.7 180000 Electrical Distribution and Electronic Control System

A.7.1 180600 Traction And High Voltage Power Distribution Subsystem

Engine System

Transmission System

Body System

Brake System

Climate Control System
Electrical Power Supply System

Electrical Distribution and Electronic Control System

$2,500 
$(547)

$1,169 

$6 

$237 $213 

$2,155 

$201 

$(1,000)

$(500)

$-

$500 

$1,000 

$1,500 

$2,000 

In

cre

m

e

ntal C

o

st D

elta

Vehicle System

Engine 

System

Transmission 

System

Electrical 

Distribution 

System

Power 

Supply

System

Climate 

Control 

System

Brake 

System

Body 

System

Net Incremental Cost Per Vehicle To Add 

Power-Split HEV Technology= $3435
Vehicle Net Sys Net Sub-Sys Net NOTES/COMPONENTS INCLUDED IN SUBSYSTEM

$ 3,435.01

$ (547.00) Importing incremental cost from previous analysis (V6 downsized to I4)

$ 1,169.27 (Note for Base Transmission we are using 2009 Toyota -6-Speed AT)

$75.26

($51.83)

($201.67) Fusion Baseline Only

($38.23) Dual Mass Fly Wheel Versus Torque Converter & Fly Wheel Assembly

$9.58

($104.92) Fusion Baseline Only

($115.34) Fusion Baseline Only

($150.00) Fusion Baseline Only

($2.41) Fusion Baseline Only

$1,602.54 Motors, Motor Control Unit, Generator Control Unit, Transmission Control Module, High 

Power Passive Components

$43.62 Aux Trans Pump & Heat Exchanger Versus Base 

l-ups in base analysis) $102.66

$6.31

$5.52 H Splash Shield Asm, Under Engine Asm

$7.99 H Trunk Close Out Battery

$12.57

1. H Duct & Shield Rear Seat to Battery Asm

2.H Duct & Shield Rear Seat to Battery A

3. H Duct Rear Seat to Battery Access Door Asm B

4. H Insulation Rear Seat Pan with Clips C

($19.76) H Rear Seat Cushion Assembly

$236.68

$80.37 Brake Pedal Assemblies

$127.81 Brake Booster & Vacuum Pump Assembly

$28.50 Additional High & Low Side Driver Estimates based additional Brake system devices

$213.46

$45.91 Auxiliary Heater Core Pump Components

$167.54 Electric versus Mechanical AC compressor

$2,154.80

($3.47) Service Battery Delta's (Based on Service Pricing)

($78.70) Base Fusion Alternator

$2,084.65

$152.31 DC-DC Converter Module

$201.50

$201.50 Main High Voltage Harness, Connectors, Brackets, etc

Rounded

$ (547) $ (547.00)

$ 1,169 $ 1,169.27

$ 6 $ 6.31

$ 237 $ 236.68

$ 213 $ 213.46
$ 2,155 $ 2,154.80

$ 201 $ 201.50

$ 3,435 $ 3,435.01


Sub-Compact Vehicle 

Segment 

(e.g Ford Fiesta)

Small/Compact Vehicle 

Segment 

(e.g Ford Focus)

010000 Engine System $ (193.35) $ (87.53)

020000 Transmission System $ 1,008.12 $ 1,026.02

030000 Body System $ 6.31 $ 6.31

060000 Brake System $ 229.83 $ 232.20

120000 Climate Control System $ 204.33 $ 207.89

140000 Electrical Power Supply System $ 1,406.23 $ 1,594.08

180000 Electrical Distribution and Electronic Control 

System $ 191.45 $ 196.19

000000 Net Incremental $ 2,852.92 $ 3,175.16

Calculated Incremental Manufacturing Cost 

System

 ID System Descriptiom

000000 Net Incremental $ 2,852.92 $ 3,175.16

Precent Decrease/Increase From Baseline 16.9% 7.6%
Midsize Vehicle 

Segment 

(Baseline: Ford Fusion)

Large Size Vehilce 

Segment

(e.g. Ford Flex)

$ (547.00) $ (131.30)

$ 1,169.27 $ 1,173.34

$ 6.31 $ 6.31

$ 236.68 $ 241.96

$ 213.46 $ 230.48

$ 2,154.80 $ 2,463.98

$ 201.50 $ 203.75

$ 3,435.01 $ 4,188.52

ted Incremental Manufacturing Cost 

010000 Engine System

020000 Transmission System

030000 Body System

060000 Brake System

120000 Climate Control System

140000 Electrical Power Supply System

180000 Electrical Distribution and Electronic Control

System

000000 Net Incremental 

System

 ID System Descriptiom

ORIGINAL CAL

$ 3,435.01 $ 4,188.52

N/A 21.9%

140000 Electrical Power Supply System

180000 Electrical Distribution and Electronic Control

System

000000 Net Incremental 

Precent Decrease/Increase From Baseline
Sub-Compact Vehicle 

Segment 

(e.g Ford Fiesta)

Small/Compact Vehicle 

Segment 

(e.g Ford Focus)

Midsize Vehicle 

Segment 

(Baseline: Ford Fusion)

Large Size Vehilce 

Segment

(e.g. Ford Flex)

$ (193.35) $ (87.53) $ (547.00) $ (131.30)

$ 1,006.86 $ 1,024.84 $ 1,168.34 $ 1,172.59

$ 5.87 $ 5.87 $ 5.87 $ 5.87

$ 229.10 $ 231.47 $ 235.95 $ 241.23

$ 204.26 $ 207.81 $ 213.38 $ 230.39

$ 1,396.96 $ 1,583.72 $ 2,141.14 $ 2,448.49

$ 188.23 $ 192.97 $ 198.28 $ 200.53

$ 2,837.93 $ 3,159.16 $ 3,415.96 $ 4,167.81

Calculated Incremental Manufacturing Cost 

ORIGINAL CALCS, PRIOR TO 

01/31/2011

$ 1,396.96 $ 1,583.72 $ 2,141.14 $ 2,448.49

$ 188.23 $ 192.97 $ 198.28 $ 200.53

$ 2,837.93 $ 3,159.16 $ 3,415.96 $ 4,167.81

16.9% 7.5% N/A 22.0%
Component Cost Basis Scaling Units Size Scaling Cost Size Cost

Primary Motor ($/kW) Mass kW 79 1.00 $ 854 60 $ 2,269

Secondary Motor ($/kW) Displacement kW 45 1.00 $ 566 30

Primary Inverter ($/kW) $7 Mass kW 79 1.00 $ 565 60 These costs need to be reviewed with FEV

Secondary Inverter ($/kW) $7 Displacement kW 45 1.00 $ 322 30

Controls $117 1x 1 1.00 $ 117

DC/DC Converter ($/kW) $90 Mass kW 2 1.29 $ 232 $ 151

Powersplit device $ 100

Powertrain EE Sub-Total 1 $ 2,756 1 $ 2,420 ($336) Difference between EPA and FEV

Cost Basis Scaling Units Size Scaling Cost Size Cost

High Voltage Wiring $204 Footprint 1 1.04 $ 213 $ 198

Supplemental heating $43 Footprint 1 1.04 $ 45 $ 44

Mechanical Transmission ($434) 1x 1 2.00 $ (868) $ (1,018)

Electric AC $460 Footprint 1 1.04 $ 479 $ 168

EPS $143 1x 1 1.00 $ 143 $ 143

Delete conventional Acc ($143) 1x 1 1.00 $ (143) $ (82)

Blended Brakes $317 1x 1 1.00 $ 317 $ 236

 Non-powetrain Sub-Total 2 $ 186 2 $ (311) ($497) Difference between EPA and FEV

Cost Basis Scaling Units

Engine Downsizing 3 $ (547) 3 $ (547)

Vehicle Sub-Total 1+2+3 $ 2,395 1+2+3 $ 1,562 ($832) Difference between EPA and FEV

Cost Basis Scaling Units Size Scaling Cost Size Cost

Battery Pack ($/kW-hr) kW 1.4 $ 1,956 1.4 $ 2,068

$ 4,351 $ 3,630 ($721) Difference between EPA and FEV

$ 1,477.25

Not costed by FEV as EPS is standard on Fusion

Minor adjustment

Minor adjustment

Battery costing needs to be discussed

 EPA Midsize Car

Power-split Cost 

Estimate

FEV Fusion 

Tear-down Results

Per FRM cost estimates

FRM? DOE Model?

Equivalent, no issue.

Equivalent, no issue.

Minor adjustment

Major adjustment. Review with FEV
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 Material Labor Burden

010101 Engine System

1 00 Engine System Top Level $ 506.26 $ 145.72 $ 518.82 $ 1,170.80 $ 17.66 $ 55.10 $ 54.28 $ 19.29 $ 146.33 $ 3.80 $ 1,320.94 $ - $ - $ - $ 715.90 $ 206.07 $ 733.66

2 02 Engine Frames, Mounting and Brackets Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

3 03 Crank Drive Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

4 04 Counter Balance Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

5 05 Cylinder Block Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

System 

ED&T/R&D

(x1000)

 Subsystem Description

Manufacturing 

Investment

(X1000)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

6 06 Cylinder Head Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

7 07 Valvetrain Subsystem $ - $ - $ - ` $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 08 Timing Drive Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 09 Accessory Drive Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 10 Intake Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 11 Fuel Induction Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 12 Exhaust Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 13 Lubrication Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 14 Cooling Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

15 15 Induction Air Charging Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

16 16 Exhaust Gas Re-Circulation Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

17 17 Breather Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

18 60 Engine Management, Engine Electronic, Electrical Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

19 70 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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 Material Labor Burden

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Item

Subsystem

System 

ED&T/R&D

(x1000)

 Subsystem Description

Manufacturing 

Investment

(X1000)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

20 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

0 NA $ 506.26 $ 145.72 $ 518.82 $ 1,170.80 $ 17.66 $ 55.10 $ 54.28 $ 19.29 $ 146.33 $ 3.80 $ 1,320.94 $ - $ - $ - $ 715.90 $ 206.07 $ 733.66

09000064810ec171.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

010101 Engine System

1 00

2 02

3 03

4 04

5 05

SYSTEM & SUBSYSTEM DESCRIPTION

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

$ 1,655.63 $ 24.98 $ 77.91 $ 76.76 $ 27.28 $ 206.93 $ 5.38 $ 1,867.94 $ - $ - $ - $ (209.64) $ (60.35) $ (214.84) $ (484.83) $ (7.32) $ (22.81) $ (22.48) $ (7.99) $ (60.60) $ (1.58) $ (547.00) $ -

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

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

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

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

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

6 06

7 07

8 08

9 09

10 10

11 11

12 12

13 13

14 14

15 15

16 16

17 17

18 60

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

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

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

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

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

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

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

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

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

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

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

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

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

19 70 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

20 0

0

End Item 

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

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

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

$ 1,655.63 $ 24.98 $ 77.91 $ 76.76 $ 27.28 $ 206.93 $ 5.38 $ 1,867.94 $ - $ - $ - $ (209.64) $ (60.35) $ (214.84) $ (484.83) $ (7.32) $ (22.81) $ (22.48) $ (7.99) $ (60.60) $ (1.58) $ (547.00) $ -

09000064810ec171.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

010101 Engine System

1 00

2 02

3 03

4 04

5 05

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Sub-Compact Vehicle Segment 

(e.g Ford Fiesta)

Small/Compact Vehicle Segment 

(e.g Ford Focu)

Large Size Vehicle Segment 

(e.g Ford Flex)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

Tooling 

(x1000)

Investment(X1

000)

6 06

7 07

8 08

9 09

10 10

11 11

12 12

13 13

14 14

15 15

16 16

17 17

18 60

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

$ - $ -

19 70 $ - $ -

09000064810ec171.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

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

20 0

0

Sub-Compact Vehicle Segment 

(e.g Ford Fiesta)

Small/Compact Vehicle Segment 

(e.g Ford Focu)

Large Size Vehicle Segment 

(e.g Ford Flex)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Tooling 

(x1000)

Investment(X1

000)

$ - $ -

$ - $ - $ (193.35) $ (87.53) $ (131.30)

I4 to I3 Credit I4 to smaller I4 V6 to smaller V6

Based on calculated I4 to smaller I4 

87.53*3/4*2

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
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 Material Labor Burden

020000 Transmission System

1 01 External Component Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 02 Case Subsystem $ 85.05 $ 16.43 $ 81.14 $ 182.62 $ 4.90 $ 7.97 $ 8.82 $ 2.10 $ 23.79 $ 1.97 $ 208.39 $ - $ - $ - $ 59.04 $ 10.47 $ 45.95 $ 115.46

3 03 Gear Train Subystem $ 74.98 $ 21.74 $ 37.08 $ 133.80 $ 1.31 $ 14.84 $ 13.45 $ 4.13 $ 33.74 $ 0.41 $ 167.95 $ - $ - $ - $ 47.93 $ 42.72 $ 91.92 $ 182.57

4 04 Internal Clutch Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 54.86 $ 37.85 $ 67.45 $ 160.16

5 05 Launch Clutch Subsystem $ 20.93 $ 11.40 $ 15.35 $ 47.67 $ 0.51 $ 1.96 $ 1.81 $ 0.30 $ 4.59 $ 0.24 $ 52.51 $ - $ - $ - $ 89.44 $ 0.46 $ 0.83 $ 90.74

BASE TECHNOL

2010 Ford Fusion, 3.0

Item

Subsystem

System 

ED&T/R&D

(x1000)

 Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Investment

(X1000)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

6 06 Oil Pump and Filter Subsystem $ 2.52 $ 1.77 $ 3.68 $ 7.97 $ 0.33 $ 0.54 $ 0.50 $ 0.21 $ 1.56 $ 0.05 $ 9.58 $ - $ - $ - $ - $ - $ - $ -

7 07 Mechanical Controls Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 15.44 $ 31.49 $ 41.23 $ 88.16

8 08A Electrical Controls Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 104.86 $ 3.94 $ 6.01 $ 114.82

9 08B Transmission Control Module (Est. $150) $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 115.34 $ 3.24 $ 11.02 $ 129.60

10 09 Parking Mechanism Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 0.30 $ 1.02 $ 0.72 $ 2.03

11 10 Misc Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 11 Electric Motor & Controls Subsystem $ 793.95 $ 208.98 $ 337.24 $ 1,340.17 $ 10.01 $ 96.40 $ 103.22 $ 49.50 $ 259.12 $ 3.25 $ 1,602.54 $ - $ - $ - $ - $ - $ - $ -

13 12 Transmission Cooling System $ 32.91 $ 13.04 $ 13.89 $ 59.84 $ 0.40 $ 5.85 $ 4.93 $ 1.55 $ 12.74 $ 0.24 $ 72.82 $ - $ - $ - $ 4.89 $ 8.99 $ 9.19 $ 23.06

14 13 OE Transmission Assembly (brokeout for eCVT only, included in 

subsystem roll-ups in base analysis) 

$ - $ 58.49 $ 44.17 $ 102.66 $ - $ - $ - $ - $ - $ - $ 102.66 $ - $ - $ - $ - $ - $ - $ -

15 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

16 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

17 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

18 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

19 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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 Material Labor Burden

BASE TECHNOL

2010 Ford Fusion, 3.0

Item

Subsystem

System 

ED&T/R&D

(x1000)

 Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Investment

(X1000)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

20 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SYSTEM ROLL-UP $1,010.34 $ 331.85 $ 532.55 $ 1,874.73 $ 17.46 $ 127.56 $ 132.73 $ 57.79 $ 335.54 $ 6.16 $ 2,216.43 $ - $ - $ - $ 492.10 $ 140.17 $ 274.33 $ 906.60

09000064810ec171.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

020000 Transmission System

1 01

2 02

3 03

4 04

5 05

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

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

$ 0.55 $ 7.18 $ 6.62 $ 2.76 $ 17.11 $ 0.56 $ 133.12 $ - $ - $ - $ 26.01 $ 5.96 $ 35.19 $ 67.17 $ 4.35 $ 0.79 $ 2.20 $ (0.65) $ 6.68 $ 1.41 $ 75.26 $ - $ -

$ 2.92 $ 16.39 $ 14.85 $ 2.35 $ 36.51 $ 0.69 $ 219.77 $ - $ - $ - $ 27.05 $ (20.98) $ (54.84) $ (48.77) $ (1.61) $ (1.55) $ (1.39) $ 1.78 $ (2.77) $ (0.29) $ (51.83) $ - $ -

$ 1.57 $ 16.17 $ 16.15 $ 4.81 $ 38.70 $ 2.81 $ 201.67 $ - $ - $ - $ (54.86) $ (37.85) $ (67.45) $ (160.16) $ (1.57) $ (16.17) $ (16.15) $ (4.81) $ (38.70) $ (2.81) $ (201.67) $ - $ -

$ - $ - $ - $ - $ - $ - $ 90.74 $ - $ - $ - $ (68.51) $ 10.93 $ 14.51 $ (43.06) $ 0.51 $ 1.96 $ 1.81 $ 0.30 $ 4.59 $ 0.24 $ (38.23) $ - $ -

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

6 06

7 07

8 08A

9 08B

10 09

11 10

12 11

13 12

14 13

15 0

16 0

17 0

18 0

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 2.52 $ 1.77 $ 3.68 $ 7.97 $ 0.33 $ 0.54 $ 0.50 $ 0.21 $ 1.56 $ 0.05 $ 9.58 $ - $ -

$ 0.59 $ 7.66 $ 7.07 $ 1.18 $ 16.50 $ 0.26 $ 104.92 $ - $ - $ - $ (15.44) $ (31.49) $ (41.23) $ (88.16) $ (0.59) $ (7.66) $ (7.07) $ (1.18) $ (16.50) $ (0.26) $ (104.92) $ - $ -

$ 0.02 $ 0.24 $ 0.22 $ 0.04 $ 0.51 $ 0.01 $ 115.34 $ - $ - $ - $ (104.86) $ (3.94) $ (6.01) $ (114.82) $ (0.02) $ (0.24) $ (0.22) $ (0.04) $ (0.51) $ (0.01) $ (115.34) $ - $ -

$ 0.65 $ 8.49 $ 7.84 $ 3.24 $ 20.23 $ 0.17 $ 150.00 $ - $ - $ - $ (115.34) $ (3.24) $ (11.02) $ (129.60) $ (0.65) $ (8.49) $ (7.84) $ (3.24) $ (20.23) $ (0.17) $ (150.00) $ - $ -

$ 0.01 $ 0.12 $ 0.14 $ 0.10 $ 0.38 $ - $ 2.41 $ - $ - $ - $ (0.30) $ (1.02) $ (0.72) $ (2.03) $ (0.01) $ (0.12) $ (0.14) $ (0.10) $ (0.38) $ - $ (2.41) $ - $ -

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 793.95 $ 208.98 $ 337.24 $ 1,340.17 $ 10.01 $ 96.40 $ 103.22 $ 49.50 $ 259.12 $ 3.25 $ 1,602.54 $ - $ -

$ 0.19 $ 2.92 $ 2.38 $ 0.64 $ 6.14 $ - $ 29.20 $ - $ - $ - $ 28.03 $ 4.06 $ 4.70 $ 36.78 $ 0.21 $ 2.93 $ 2.55 $ 0.91 $ 6.60 $ 0.24 $ 43.62 $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 58.49 $ 44.17 $ 102.66 $ - $ - $ - $ - $ - $ - $ 102.66 $ - $ -

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

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

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

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

19 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

20 0

End Item 

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

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

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

$ 6.51 $ 59.17 $ 55.27 $ 15.12 $ 136.07 $ 4.49 $ 1,047.17 $ - $ - $ - $ 518.23 $ 191.68 $ 258.22 $ 968.13 $ 10.95 $ 68.39 $ 77.46 $ 42.68 $ 199.47 $ 1.66 $ 1,169.27 $ - $ -

09000064810ec171.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

020000 Transmission System

1 01

2 02

3 03

4 04

5 05

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

Sub-Compact Vehicle Segment 

(e.g Ford Fiesta)

Small/Compact Vehicle Segment 

(e.g Ford Focus)

Large Size Vehicle Segment 

(e.g Ford Flex)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

$ -

$ - $ 172.93 $ 187.16 $ 246.67

$ - $ 140.66 $ 151.59 $ 184.25

$ - $ 52.51 $ 52.51 $ 52.51

$ -

Investment(X1

000)

6 06

7 07

8 08A

9 08B

10 09

11 10

12 11

13 12

14 13

15 0

16 0

17 0

18 0

$ - $ 8.24 $ 8.78 $ 11.02

$ -

$ -

$ -

$ -

$ -

$ - $ 1,332.39 $ 1,393.94 $ 1,739.59

$ - $ 62.12 $ 66.41 $ 84.56

$ - $ 102.66 $ 102.66 $ 102.66

$ -

$ -

$ -

$ -

19 0 $ -

09000064810ec171.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

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

20 0

Sub-Compact Vehicle Segment 

(e.g Ford Fiesta)

Small/Compact Vehicle Segment 

(e.g Ford Focus)

Large Size Vehicle Segment 

(e.g Ford Flex)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Investment(X1

000)

$ -

$ - $ 1,871.51 $ 1,963.05 $ 2,421.25

BASE $ 863.40 $ 937.03 $ 1,247.91

DELTA $ 1,008.12 $ 1,026.02 $ 1,173.34

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
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 Material Labor Burden

030000 Body System

1 01 Body Structure Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 02 Front End Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

3 03 Body Closures Subsystem $ 9.04 $ 4.24 $ 3.65 $ 16.94 $ 0.18 $ 2.24 $ 2.13 $ 0.67 $ 5.22 $ - $ 22.16 $ - $ - $ - $ 7.31 $ 2.75 $ 2.61 $ 12.67

4 04 Second Unit Body Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

5 05 Interior Trim and Ornamentation Subsystem $ 4.74 $ 1.00 $ 1.03 $ 6.77 $ 0.04 $ 0.52 $ 0.48 $ 0.18 $ 1.22 $ - $ 7.99 $ - $ - $ - $ - $ - $ - $ -

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

I

(x1000) tem

Subsystem

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

BASE TECHNOLOG

2010 Ford Fusion, 3.0L V

System 

ED&T/R&D

(x1000)

 Subsystem Description Investment

(X1000)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

6 06 Sound and Heat Control Subsystem (Body) $ 5.21 $ 3.10 $ 1.66 $ 9.98 $ 0.08 $ 1.05 $ 0.97 $ 0.32 $ 2.42 $ 0.17 $ 12.57 $ - $ - $ - $ - $ - $ - $ -

7 07 Sealing Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 10 Seating Subsystem $ 13.77 $ 9.76 $ 6.72 $ 30.24 $ 0.29 $ 3.83 $ 3.53 $ 1.09 $ 8.75 $ - $ 38.99 $ - $ - $ - $ 17.57 $ 15.28 $ 12.28 $ 45.13

9 12 Instrument Panel and Console Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

15 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

16 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

17 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

18 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

19 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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 Material Labor Burden

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

I

(x1000) tem

Subsystem

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

BASE TECHNOLOG

2010 Ford Fusion, 3.0L V

System 

ED&T/R&D

(x1000)

 Subsystem Description Investment

(X1000)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

20 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SYSTEM ROLL-UP $ 32.76 $ 18.10 $ 13.06 $ 63.92 $ 0.59 $ 7.64 $ 7.11 $ 2.27 $ 17.62 $ 0.17 $ 81.71 $ - $ - $ - $ 24.88 $ 18.04 $ 14.89 $ 57.81

09000064810ec171.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

030000 Body System

1 01

2 02

3 03

4 04

5 05

SYSTEM & SUBSYSTEM DESCRIPTION

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

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

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

$ 0.14 $ 1.69 $ 1.63 $ 0.52 $ 3.97 $ - $ 16.64 $ - $ - $ - $ 1.73 $ 1.49 $ 1.04 $ 4.26 $ 0.04 $ 0.55 $ 0.51 $ 0.16 $ 1.26 $ - $ 5.52 $ - $ -

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 4.74 $ 1.00 $ 1.03 $ 6.77 $ 0.04 $ 0.52 $ 0.48 $ 0.18 $ 1.22 $ - $ 7.99 $ - $ -

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

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:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

6 06

7 07

8 10

9 12

10 0

11 0

12 0

13 0

14 0

15 0

16 0

17 0

18 0

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 5.21 $ 3.10 $ 1.66 $ 9.98 $ 0.08 $ 1.05 $ 0.97 $ 0.32 $ 2.42 $ 0.17 $ 12.57 $ - $ -

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

$ 0.46 $ 5.98 $ 5.51 $ 1.68 $ 13.62 $ - $ 58.75 $ - $ - $ - $ (3.81) $ (5.53) $ (5.56) $ (14.89) $ (0.16) $ (2.15) $ (1.97) $ (0.58) $ (4.87) $ - $ (19.76) $ - $ -

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

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

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

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

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

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

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

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

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

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

19 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

20 0

End Item 

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

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

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:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

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

$ 0.60 $ 7.67 $ 7.13 $ 2.19 $ 17.59 $ - $ 75.39 $ - $ - $ - $ 7.87 $ 0.07 $ (1.82) $ 6.12 $ (0.00) $ (0.02) $ (0.02) $ 0.08 $ 0.03 $ 0.17 $ 6.31 $ - $ -

09000064810ec171.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

030000 Body System

1 01

2 02

3 03

4 04

5 05

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Sub-Compact Vehicle Segment 

(e.g Ford Fiesta)

Small/Compact Vehicle Segment 

(e.g Ford Focus)

Large Size Vehicle Segment 

(e.g Ford Flex)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

$ - $ -

$ - $ -

$ - $ 5.52 $ 5.52 $ 5.52

$ - $ - $ - $ -

$ - $ 7.99 $ 7.99 $ 7.99

Investment(X1

000)

6 06

7 07

8 10

9 12

10 0

11 0

12 0

13 0

14 0

15 0

16 0

17 0

18 0

$ - $ 12.57 $ 12.57 $ 12.57

$ - $ - $ - $ -

$ - $ (19.76) $ (19.76) $ (19.76)

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

19 0 $ -

09000064810ec171.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

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

20 0

Sub-Compact Vehicle Segment 

(e.g Ford Fiesta)

Small/Compact Vehicle Segment 

(e.g Ford Focus)

Large Size Vehicle Segment 

(e.g Ford Flex)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Investment(X1

000)

$ -

$ - 6.31 6.31 6.31

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
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 Material Labor Burden

06 Brake System

1 03 Front Rotor Subsystems $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 04 Rear Rotor Subsystems $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

3 05 Parking Brake and Actuation Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

4 06 Brake Actuation Subsystem $ 43.46 $ 17.00 $ 21.17 $ 81.63 $ 1.02 $ 8.71 $ 7.29 $ 2.19 $ 19.20 $ 0.29 $ 101.12 $ - $ - $ - $ 7.13 $ 3.44 $ 7.43 $ 18.01

5 07 Power Brake Subsystem (for Hydraulic) $ 48.11 $ 33.65 $ 44.27 $ 126.03 $ 0.74 $ 10.29 $ 8.98 $ 3.18 $ 23.19 $ 0.22 $ 149.44 $ - $ - $ - $ 6.95 $ 6.47 $ 5.07 $ 18.49

BASE TECHNOLO

2010 Ford Fusion, 3.0L 

Item

Subsystem

System 

ED&T/R&D

(x1000)

 Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Investment

(X1000)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

6 09 Brake Controls Subsystem $ 21.96 $ 0.62 $ 2.10 $ 24.68 $ 0.12 $ 1.60 $ 1.48 $ 0.62 $ 3.82 $ - $ 28.50 $ - $ - $ - $ - $ - $ - $ -

7 10 Auxillary Brake Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 0 Na $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

15 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

16 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

17 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

18 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

19 0 NA $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ - $ $ - $ $ - $ $ -

09000064810ec171.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 Material Labor Burden

BASE TECHNOLO

2010 Ford Fusion, 3.0L 

Item

Subsystem

System 

ED&T/R&D

(x1000)

 Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Investment

(X1000)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

20 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SYSTEM ROLL-UP $ 113.54 $ 51.26 $ 67.54 $ 232.34 $ 1.88 $ 20.60 $ 17.75 $ 5.98 $ 46.21 $ 0.51 $ 279.06 $ - $ - $ - $ 14.08 $ 9.91 $ 12.51 $ 36.50

09000064810ec171.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

06 Brake System

1 03

2 04

3 05

4 06

5 07

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

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

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

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

$ 0.08 $ 1.11 $ 1.06 $ 0.40 $ 2.64 $ 0.10 $ 20.75 $ - $ - $ - $ 36.33 $ 13.56 $ 13.74 $ 63.62 $ 0.94 $ 7.59 $ 6.23 $ 1.79 $ 16.55 $ 0.20 $ 80.37 $ - $ -

$ 0.10 $ 1.34 $ 1.21 $ 0.47 $ 3.12 $ 0.02 $ 21.63 $ - $ - $ - $ 41.16 $ 27.17 $ 39.20 $ 107.54 $ 0.64 $ 8.95 $ 7.77 $ 2.71 $ 20.07 $ 0.20 $ 127.81 $ - $ -

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

6 09

7 10

8 0

9 0

10 0

11 0

12 0

13 0

14 0

15 0

16 0

17 0

18 0

19 0

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 21.96 $ 0.62 $ 2.10 $ 24.68 $ 0.12 $ 1.60 $ 1.48 $ 0.62 $ 3.82 $ - $ 28.50 $ - $ -

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

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

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

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

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

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

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

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

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

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

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

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

19 0 $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ -

09000064810ec171.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

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

20 0

End Item 

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

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

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

$ 0.18 $ 2.45 $ 2.27 $ 0.87 $ 5.76 $ 0.12 $ 42.39 $ - $ - $ - $ 99.45 $ 41.35 $ 55.03 $ 195.83 $ 1.70 $ 18.14 $ 15.48 $ 5.12 $ 40.45 $ 0.40 $ 236.68 $ - $ -

09000064810ec171.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

06 Brake System

1 03

2 04

3 05

4 06

5 07

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

Sub-Compact Vehicle Segment 

(e.g Ford Fiesta)

Small/Compact Vehicle Segment 

(e.g Ford Focus)

Large Size Vehicle Segment 

(e.g Ford Flex)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

$ -

$ -

$ -

$ - $ 80.37 $ 80.37 $ 80.37

$ - $ 120.96 $ 123.33 $ 133.09

Investment(X1

000)

6 09

7 10

8 0

9 0

10 0

11 0

12 0

13 0

14 0

15 0

16 0

17 0

18 0

19 0

$ - $ 28.50 $ 28.50 $ 28.50

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

19 0 $ -

09000064810ec171.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

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

20 0

Sub-Compact Vehicle Segment 

(e.g Ford Fiesta)

Small/Compact Vehicle Segment 

(e.g Ford Focus)

Large Size Vehicle Segment 

(e.g Ford Flex)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Investment(X1

000)

$ -

$ - 229.83 232.20 241.96

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
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 Material Labor Burden

09 Exhaust System

1 01 Acoustical Control Components Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 02 Exhaust Gas Treatment Components Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

3 05 Exhaust Modules $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

4 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

5 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

BASE TECHNOLOG

2010 Ford Fusion, 3.0L V

Item

Subsystem

System 

ED&T/R&D

(x1000)

 Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Investment

(X1000)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

Differences captured as part of Engine 

Downsizing Credit

6 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

7 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

15 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

16 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

17 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

18 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

Downsizing Credit

19 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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 Material Labor Burden

BASE TECHNOLOG

2010 Ford Fusion, 3.0L V

Item

Subsystem

System 

ED&T/R&D

(x1000)

 Subsystem Description

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

(x1000)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Investment

(X1000)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

20 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SYSTEM ROLL-UP $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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

09 Exhaust System

1 01

2 02

3 05

4 0

5 0

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

End Item 

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

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

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

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

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

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

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

6 0

7 0

8 0

9 0

10 0

11 0

12 0

13 0

14 0

15 0

16 0

17 0

18 0

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

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

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

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

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

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

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

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

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

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

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

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

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

19 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

20 0

End Item 

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

BASE TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

Net 

Component/ 

Assembly 

Cost Impact to 

OEM

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

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

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

09000064810ec171.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

09 Exhaust System

1 01

2 02

3 05

4 0

5 0

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

$ -

$ -

$ -

$ -

$ -

Investment(X1

000)

6 0

7 0

8 0

9 0

10 0

11 0

12 0

13 0

14 0

15 0

16 0

17 0

18 0

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

19 0 $ -

09000064810ec171.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

Item

Subsystem

SYSTEM & SUBSYSTEM DESCRIPTION

20 0

Investment(X1

000)

$ -

$ -

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
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 Material Labor Burden

12 Climate Control System

1 01 Air Handling/Body Ventilation Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 02 Heating Defrosting Subsystem $ 27.27 $ 5.53 $ 5.27 $ 38.07 $ 0.27 $ 2.89 $ 3.11 $ 1.43 $ 7.69 $ 0.15 $ 45.91 $ - $ - $ - $ - $ - $ - $ -

3 03 Refrigeration/Air Conditioning Subsystem $ 148.86 $ 23.86 $ 43.32 $ 216.04 $ 1.85 $ 14.57 $ 13.38 $ 5.46 $ 35.25 $ - $ 251.30 $ - $ - $ - $ 24.10 $ 19.18 $ 25.92 $ 69.20

4 04 Controls Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

5 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

I

(x1000) tem

Subsystem

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

BASE TECHNOLO

2010 Ford Fusion, 3.0L 

System 

ED&T/R&D

(x1000)

 Subsystem Description Investment

(X1000)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

6 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

7 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

15 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

16 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

17 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

18 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

19 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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 Material Labor Burden

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

I

(x1000) tem

Subsystem

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

BASE TECHNOLO

2010 Ford Fusion, 3.0L 

System 

ED&T/R&D

(x1000)

 Subsystem Description Investment

(X1000)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

20 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SYSTEM ROLL-UP $ 176.13 $ 29.38 $ 48.59 $ 254.11 $ 2.12 $ 17.46 $ 16.48 $ 6.89 $ 42.95 $ 0.15 $ 297.21 $ - $ - $ - $ 24.10 $ 19.18 $ 25.92 $ 69.20

09000064810ec171.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

12 Climate Control System

1 01

2 02

3 03

4 04

5 0

SYSTEM & SUBSYSTEM DESCRIPTION

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

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 27.27 $ 5.53 $ 5.27 $ 38.07 $ 0.27 $ 2.89 $ 3.11 $ 1.43 $ 7.69 $ 0.15 $ 45.91 $ - $ -

$ 0.58 $ 6.52 $ 5.56 $ 1.89 $ 14.56 $ 83.75 $ - $ - $ - $ 124.76 $ 4.68 $ 17.40 $ 146.85 $ 1.27 $ 8.04 $ 7.82 $ 3.57 $ 20.70 $ - $ 167.54 $ - $ -

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

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

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

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:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

6 0

7 0

8 0

9 0

10 0

11 0

12 0

13 0

14 0

15 0

16 0

17 0

18 0

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

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

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

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

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

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

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

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

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

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

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

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

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

19 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

20 0

End Item 

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

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

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:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

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

$ 0.58 $ 6.52 $ 5.56 $ 1.89 $ 14.56 $ - $ 83.75 $ - $ - $ - ###### $ 10.21 $ 22.67 $ 184.91 $ 1.53 $ 10.94 $ 10.93 $ 5.00 $ 28.39 $ 0.15 $ 213.46 $ - $ -

09000064810ec171.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

12 Climate Control System

1 01

2 02

3 03

4 04

5 0

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Sub-Compact Vehicle Segment 

(e.g Ford Fiesta)

Small/Compact Vehicle Segment 

(e.g Ford Fusion)

Large Size Vehicle Segment 

(e.g Ford Flex)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

$ -

$ - 41.07 42.95 54.94

$ - 163.26 164.93 175.53

$ -

$ -

Investment(X1

000)

6 0

7 0

8 0

9 0

10 0

11 0

12 0

13 0

14 0

15 0

16 0

17 0

18 0

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

19 0 $ -

09000064810ec171.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

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

20 0

Sub-Compact Vehicle Segment 

(e.g Ford Fiesta)

Small/Compact Vehicle Segment 

(e.g Ford Fusion)

Large Size Vehicle Segment 

(e.g Ford Flex)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Investment(X1

000)

$ -

$ - 204.33 207.89 230.48

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
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 Material Labor Burden

14 Electrical Power Supply System

1 01 Service Battery Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 3.00 $ - $ - $ 3.00

2 02 Generator/Alternator and Regulator Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 29.50 $ 11.05 $ 27.95 $ 68.50

3 03 High Voltage Traction Battery Subsystem $ 1,294.46 $ 170.68 $ 293.87 $ 1,759.01 $ 13.57 $ 119.20 $ 128.32 $ 61.13 $ 322.21 $ 3.44 $ 2,084.65 $ - $ - $ - $ - $ - $ - $ -

4 05 Voltage Converter / Inverter Subsystem $ 89.13 $ 20.84 $ 21.83 $ 131.80 $ 0.66 $ 8.56 $ 7.89 $ 3.27 $ 20.38 $ 0.13 $ 152.31 $ - $ - $ - $ - $ - $ - $ -

5 08 Energy Management Module Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

I

(x1000) tem

Subsystem

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

BASE TECHNOL

2010 Ford Fusion, 3.0

System 

ED&T/R&D

(x1000)

 Subsystem Description Investment

(X1000)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

6 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

7 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

15 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

16 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

17 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

18 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

19 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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 Material Labor Burden

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

I

(x1000) tem

Subsystem

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

BASE TECHNOL

2010 Ford Fusion, 3.0

System 

ED&T/R&D

(x1000)

 Subsystem Description Investment

(X1000)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

20 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SYSTEM ROLL-UP ######## $ 191.52 $ 315.70 $ 1,890.81 $ 14.22 $ 127.76 $ 136.21 $ 64.40 $ 342.59 $ 3.56 $ 2,236.96 $ - $ - $ - $ 32.50 $ 11.05 $ 27.95 $ 71.50

09000064810ec171.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

14 Electrical Power Supply System

1 01

2 02

3 03

4 05

5 08

SYSTEM & SUBSYSTEM DESCRIPTION

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

$ 0.02 $ 0.20 $ 0.18 $ 0.08 $ 0.47 $ - $ 3.47 $ - $ - $ - $ (3.00) $ - $ - $ (3.00) $ (0.02) $ (0.20) $ (0.18) $ (0.08) $ (0.47) $ - $ (3.47) $ - $ -

$ 0.33 $ 4.23 $ 3.90 $ 1.63 $ 10.08 $ 0.13 $ 78.70 $ - $ - $ - $ (29.50) $ (11.05) $ (27.95) $ (68.50) $ (0.33) $ (4.23) $ (3.90) $ (1.63) $ (10.08) $ (0.13) $ (78.70) $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 1,294.46 $ 170.68 $ 293.87 $ 1,759.01 $ 13.57 $ 119.20 $ 128.32 $ 61.13 $ 322.21 $ 3.44 $ 2,084.65 $ - $ -

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 89.13 $ 20.84 $ 21.83 $ 131.80 $ 0.66 $ 8.56 $ 7.89 $ 3.27 $ 20.38 $ 0.13 $ 152.31 $ - $ -

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

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

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:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

6 0

7 0

8 0

9 0

10 0

11 0

12 0

13 0

14 0

15 0

16 0

17 0

18 0

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

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

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

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

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

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

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

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

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

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

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

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

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

19 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

20 0

End Item 

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

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

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:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

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

$ 0.34 $ 4.42 $ 4.08 $ 1.70 $ 10.54 $ 0.13 $ 82.17 $ - $ - $ - ######## $ 180.47 $ 287.75 $ 1,819.31 $ 13.88 $ 123.34 $ 132.13 $ 62.70 $ 332.05 $ 3.44 $ 2,154.80 $ - $ -

09000064810ec171.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

14 Electrical Power Supply System

1 01

2 02

3 03

4 05

5 08

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Sub-Compact Vehicle Segment 

(e.g Ford Fiesta)

Small/Compact Vehicle Segment 

(e.g Ford Fusion)

Large Size Vehicle Segment 

(e.g Ford Flex)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

$ - -3.47 -3.47 -3.47

$ - -56.92 -61.23 -90.55

$ - 1314.30 1506.47 2405.68

$ - 152.31 152.31 152.31

$ -

Investment(X1

000)

6 0

7 0

8 0

9 0

10 0

11 0

12 0

13 0

14 0

15 0

16 0

17 0

18 0

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

19 0 $ -

09000064810ec171.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

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

20 0

Sub-Compact Vehicle Segment 

(e.g Ford Fiesta)

Small/Compact Vehicle Segment 

(e.g Ford Fusion)

Large Size Vehicle Segment 

(e.g Ford Flex)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Investment(X1

000)

$ -

$ - 1406.23 1594.08 2463.98

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411
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 Material Labor Burden

18 Electrical Distribution and Electronic Control System

1 01 Electrical Wiring and Circuit Protection Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

2 03 Electrical Distribution Switches Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

3 04 Miscellaneous Electrical Devices Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

4 06 Traction And High Voltage Power Distribution Subsystem $ 127.00 $ 32.43 $ 16.16 $ 175.58 $ 0.81 $ 10.64 $ 9.75 $ 4.03 $ 25.23 $ 0.68 $ 201.50 $ - $ - $ - $ - $ - $ - $ -

5 07 Power Electric Center (PEC) Subsystem $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

I

(x1000) tem

Subsystem

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

BASE TECHNOLO

2010 Ford Fusion, 3.0L 

System 

ED&T/R&D

(x1000)

 Subsystem Description Investment

(X1000)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

6 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

7 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

8 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

9 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

10 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

11 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

12 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

13 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

14 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

15 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

16 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

17 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

18 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

19 0 NA $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ $ - $ - $ $ - $ $ - $ $ -

20 0 NA $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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 Material Labor Burden

SYSTEM & SUBSYSTEM DESCRIPTION

NEW TECHNOLOGY GENERAL PART INFORMATION:

2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), 

(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Tooling 

I

(x1000) tem

Subsystem

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup Net 

Component/ 

Assembly 

Cost Impact to 

OEM

Total Markup 

Cost 

(Component/ 

Assembly)

Total 

Packaging 

Cost 

(Component

/ Assembly)

BASE TECHNOLO

2010 Ford Fusion, 3.0L 

System 

ED&T/R&D

(x1000)

 Subsystem Description Investment

(X1000)

Technology Level: Power-Split HEV Technology

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

Study Case#: 0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

SYSTEM ROLL-UP $ 127.00 $ 32.43 $ 16.16 $ 175.58 $ 0.81 $ 10.64 $ 9.75 $ 4.03 $ 25.23 $ 0.68 $ 201.50 $ - $ - $ - $ - $ - $ - $ -

09000064810ec171.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

18 Electrical Distribution and Electronic Control System

1 01

2 03

3 04

4 06 

5 07

SYSTEM & SUBSYSTEM DESCRIPTION

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

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

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

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

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ 127.00 $ 32.43 $ 16.16 $ 175.58 $ 0.81 $ 10.64 $ 9.75 $ 4.03 $ 25.23 $ 0.68 $ 201.50 $ - $ -

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

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

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:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

6 0

7 0

8 0

9 0

10 0

11 0

12 0

13 0

14 0

15 0

16 0

17 0

18 0

19 0

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

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

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

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

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

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

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

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

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

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

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

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

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

19 0 $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ - $ -

20 0

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

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

09000064810ec171.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

SYSTEM & SUBSYSTEM DESCRIPTION

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

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

System 

ED&T/R&D

(x1000)

Tooling 

(x1000)

Investment

(X1000)

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:

2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE

Manufacturing Total 

Manufacturing 

Cost 

(Component/ 

Assembly)

Markup

Total Markup 

Cost 

(Component/ 

Assembly)

$ - $ - $ - $ - $ - $ - $ - $ - $ - $ - ###### $ 32.43 $ 16.16 $ 175.58 $ 0.81 $ 10.64 $ 9.75 $ 4.03 $ 25.23 $ 0.68 $ 201.50 $ - $ -

09000064810ec171.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

18 Electrical Distribution and Electronic Control System

1 01

2 03

3 04

4 06 

5 07

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Sub-Compact Vehicle Segment 

(e.g Ford Fiesta)

Small/Compact Vehicle Segment 

(e.g Ford Fusion)

Large Size Vehicle Segment 

(e.g Ford Flex)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

$ -

$ -

$ -

$ - 191.45 196.19 203.75

$ -

Investment(X1

000)

6 0

7 0

8 0

9 0

10 0

11 0

12 0

13 0

14 0

15 0

16 0

17 0

18 0

19 0

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

$ -

19 0 $ -

20 0

$ -

$ -

09000064810ec171.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

SYSTEM & SUBSYSTEM DESCRIPTION

Item

Subsystem

Sub-Compact Vehicle Segment 

(e.g Ford Fiesta)

Small/Compact Vehicle Segment 

(e.g Ford Fusion)

Large Size Vehicle Segment 

(e.g Ford Flex)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Scaling Factor Relative to Baseline 

(Ford Fusion)

Investment(X1

000)

$ - 191.45 196.19 203.75

09000064810ec171.xls

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

Author: G. Kolwich

(248)373-6000 Ext. 2411