### 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 BurdenItem **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**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 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** 

**$ VEHICLE 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



# 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** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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**$ -** 

**$ -** 

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**$ -** 

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**- $**  **-**

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**$ -** 

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**$ -** 

**$ -** 

**$ -** 

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**$ -** 

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**$ -** 

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**- $**  **-**

**$ -** 

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**$ -** 

**$ -** 

**$ 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** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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**$ -** 

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**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 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** 

**$ -** 

**$**

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**$ -** 

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**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 127.00** 

**$ 32.43** 

**$ 16.16** 

**$ 175.58** 

**$ 0.81** 

**$ 10.64** 

**$ 9.75** 

**$ 4.03** 

**$ 25.23** 

**$ 0.68** 

**$ 201.50** 

**$ -** 

**$**



### 19 **19 -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### 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 DRAFTItem 

# 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 DRAFTItem 

# 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 120200Heating Defrosting Subsystem A.5.2 120300Refrigeration/Air Conditioning Subsystem A.6 **140000 Electrical Power Supply System**  A.6.1 140100Service Battery Subsystem A.6.2 140200Generator/Alternator and Regulator Subsystem A.6.3 140300High Voltage Traction Battery Subsystem A.6.4 140500Voltage Converter / Inverter Subsystem A.7 **180000 Electrical Distribution and Electronic Control System**  A.7.1 180600Traction 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** **I n** **c r** **e m** **e n** **t a** **l C** **o s** **t D** **e l** **t a** 



# Vehicle System

**Engine System**  **Tr**

**ansmission 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 OE Transmission Assembly (broke out for eCVT only, included in subsystem roll-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

$ **16.9% 7.6%**  **Precent Decrease/Increase From Baseline**

# 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

$ **Calculated Incremental Manufacturing Cost**



# 010000 EngineSystem 020000 Transmission System 030000 Body

System 060000 BrakeSystem 120000 Climate ControlSystem 140000 Electrical PowerSupply System 180000 Electrical Distributionand Electronic Control

System 000000 Net

Incremental 

# System **ID System** **Descriptiom**



# ORIGINALCALCS, PRIOR TO

**3,435.01 $**  4,188.52

$ **N/A 21.9%**  

# 140000 Electrical PowerSupply System 180000 Electrical Distributionand Electronic Control

System 000000 Net

Incremental **Precent Decrease/Increase From Baseline**

# Sub-Compact Vehicle

**Segment (e.g Ford Fiesta)**  **Small/C ompact Vehicle**  **Se gment**  **(e. g Ford Focus)**  **Midsize Vehicle Se** **gm ent**  **(Basel ine: 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

$ **Cal culated Incremental Manufacturing Cost** 



# ORIGINALCALCS, 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 A**C** $460 Footprint 1 1.04 479 $ 168 $ 

# EPS $143 1x 1 1.00 143 $ 143 $ 

# Delete conventional A**cc** ($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 Sy**stem**

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)** ItemSubsystem **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)** ItemSubsystem **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 Sy**stem**

1 **00** 2 **02** 3 **03** 4 **04** 5 **05**

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem

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 -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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### 19 **70 -** 

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### 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 DESCRIPTIONItemSubsystem



### 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** 

**- $**  **-**

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**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 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 Sy**stem**

1 **00** 2 **02** 3 **03** 4 **04** 5 **05**

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem **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 -** 

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**- $**  **-**

**$**



### 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 DESCRIPTIONItemSubsystem



### 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 Sy**stem**

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 TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem **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**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 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 TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem **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**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 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** 

**$ 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



# 020000 Transmission Sy**stem**

1 **01** 2 **02** 3 **03** 4 **04** 5 **05**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

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

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 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 -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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**$ -** 

**$ 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)** 

**$ -** 

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**- $**  **-**

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**- $**  **-**

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**$ 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** 

**$ -** 

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**$ 58.49** 

**$ 44.17** 

**$ 102.66** 

**$ -** 

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**$ 102.66** 

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### 19 **0 -** 

**$ -** 

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### 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 DRAFTItemSubsystem 

# 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)**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

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**$ -** 

**$**



### 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 Sy**stem**

1 **01** 2 **02** 3 **03** 4 **04** 5 **05**ItemSubsystem 

# 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 DRAFTItemSubsystem 

# 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

**Sy stem** 

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**  **(x1000)**ItemSubsystem 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 TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

**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**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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### 11 **0 NA**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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### 12 **0 NA**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

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**$ -** 

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### 13 **0 NA**  **- $**  **-**

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### 14 **0 NA**  **- $**  **-**

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### 15 **0 NA**  **- $**  **-**

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### 16 **0 NA**  **- $**  **-**

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### 17 **0 NA**  **- $**  **-**

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### 18 **0 NA**  **- $**  **-**

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### 19 **0 NA**  **- $**  **-**

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### 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)**ItemSubsystem 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 TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

**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**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### 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** 

**$ 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



# 030000 Body

**Sy stem** 

1 **01** 2 **02** 3 **03** 4 **04** 5 **05**

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem

End Item

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

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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**$ -** 

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**$**

**- $**  **-**

**$ -** 

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**$ 0.18** 

**$ 1.22** 

**$ -** 

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**$ 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**

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### 19 **0 -** 

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### 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 DESCRIPTIONItemSubsystem



### 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)** 

**- $**  **-**

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### 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

**Sy stem** 

1 **01** 2 **02** 3 **03** 4 **04** 5 **05**

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem **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) $** 

**- $** 

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**- $** 

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**- $** 

**- $** 

**- $** 

**- $** 

**- $** 



### 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 DESCRIPTIONItemSubsystem



### 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 Sy stem** 

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

**$ -** 

**$ -** 

**$ -** 

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### 2 **04 Rear Rotor Subsystems**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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**$ -** 

**$ -** 

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

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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**$ -** 

**$ -** 

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**$ -** 

**$ -** 

**$ -** 

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**$** 

### 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 TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem **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**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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### 8 **0 Na**  **- $**  **-**

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### 9 **0 NA**  **- $**  **-**

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### 18 **0 NA**  **- $**  **-**

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### 19 **0 NA**  **- $**  **-**

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### 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 TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem **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**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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### 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** 

**$ 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



# 06**Brake Sy stem** 

1 **03** 2 **04** 3 **05** 4 **06** 5 **07**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

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

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# 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)**



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### 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 DRAFTItemSubsystem 

# 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)**

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### 0.18 **$ 2.45** 

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**$ 236.68** 

**$ -** 

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**$**



### 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 Sy stem** 

1 **03** 2 **04** 3 **05** 4 **06** 5 **07**ItemSubsystem 

# 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**  **$**

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### 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 DRAFTItemSubsystem 

# 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 Sy stem** 

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

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

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### 3 **05 Exhaust Modules**  **- $**  **-**

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### 4 **0 NA**  **- $**  **-**

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### 5 **0 NA**  **- $**  **-**

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# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem **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 DownsizingCredit 6 **0 NA**  **- $**  **-**

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### 16 **0 NA**  **- $**  **-**

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### 17 **0 NA**  **- $**  **-**

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### 18 **0 NA**  **- $**  **-**

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# DownsizingCredit

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

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### 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 TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem **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**  **- $**  **-**

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### -

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**$ 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 Sy stem** 

1 **01** 2 **02** 3 **05** 4 **0** 5 **0**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

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

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# 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**

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### 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 DRAFTItemSubsystem 

# 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)**

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### 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 Sy stem** 

1 **01** 2 **02** 3 **05** 4 **0** 5 **0**ItemSubsystem 

# 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**

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### 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 DRAFTItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

20 **0 Investment(X1** 

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### 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 Sy stem** 

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

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### 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** 

**$ -** 

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### 3 **03 Refrigeration/Air Conditioning Subsystem**  **148.86 $**  **23.86**

**$ 43.32** 

**$ 216.04** 

**$ 1.85** 

**$ 14.57** 

**$ 13.38** 

**$ 5.46** 

**$ 35.25** 

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**$ 251.30** 

**$ -** 

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**$ 24.10** 

**$ 19.18** 

**$ 25.92** 

**$ 69.20** 

**$** 

### 4 **04 Controls Subsystem**  **- $**  **-**

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### 5 **0 NA**  **- $**  **-**

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# 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)**ItemSubsystem 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 TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

**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**  **- $**  **-**

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### 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)**ItemSubsystem 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 TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

**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**  **- $**  **-**

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### 176.13 **$ 29.38** 

**$ 48.59** 

**$ 254.11** 

**$ 2.12** 

**$ 17.46** 

**$ 16.48** 

**$ 6.89** 

**$ 42.95** 

**$ 0.15** 

**$ 297.21** 

**$ -** 

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### 24.10

**$ 19.18** 

**$ 25.92** 

**$ 69.20** 

**$ 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



# 12**Climate Control Sy stem** 

1 **01** 2 **02** 3 **03** 4 **04** 5 **0**

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem

End Item

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

**- $**  **-**

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**$ 27.27** 

**$ 5.53** 

**$ 5.27** 

**$ 38.07** 

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**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)** 



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### 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 DESCRIPTIONItemSubsystem



### 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)** 

**- $**  **-**

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### 0.58 **$ 6.52** 

**$ 5.56** 

**$ 1.89** 

**$ 14.56** 

**$ -** 

**$ 83.75** 

**$ -** 

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**$** 

### ###### **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 Sy stem** 

1 **01** 2 **02** 3 **03** 4 **04** 5 **0**

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem **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 -** 

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### 19 **0 -** 

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### 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 DESCRIPTIONItemSubsystem



### 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 Pow er Supply**  **Sy stem** 

1 **01 Service Battery Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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**$ -** 

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**$ 3.00** 

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**$ 3.00** 

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### 2 **02 Generator/Alternator and Regulator Subsystem**  **- $**  **-**

**$ -** 

**$ -** 

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**$ 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** 

**$ -** 

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### 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** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

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**$ -** 

**$ -** 

**$ -** 

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**$** 

# 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)**ItemSubsystem 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 TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

**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**  **- $**  **-**

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### 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)**ItemSubsystem 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 TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

**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**  **- $**  **-**

**$ -** 

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### ######## **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** 

**$ 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



# 14**Electrical Pow er Supply**  **Sy stem** 

1 **01** 2 **02** 3 **03** 4 **05** 5 **08**

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem

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** 

**$ -** 

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**$ 0.33**  **$ 4.23** 

**$ 3.90** 

**$ 1.63** 

**$ 10.08** 

**$ 0.13** 

**$ 78.70** 

**$ -** 

**$ -** 

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**$ (29.50)** 

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**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)** 



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### 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 DESCRIPTIONItemSubsystem



### 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)** 

**- $**  **-**

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### 0.34 **$ 4.42** 

**$ 4.08** 

**$ 1.70** 

**$ 10.54** 

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**$ 82.17** 

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**$** 

### ######## **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 Pow er Supply**  **Sy stem** 

1 **01** 2 **02** 3 **03** 4 **05** 5 **08**

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem **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**

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### 19 **0 -** 

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### 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 DESCRIPTIONItemSubsystem



### 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 Sy stem** 

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

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

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

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### 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** 

**$ -** 

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

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# 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)**ItemSubsystem 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 TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

**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**  **- $**  **-**

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### 7 **0 NA**  **- $**  **-**

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### 20 **0 NA**  **- $**  **-**

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### 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)**ItemSubsystem 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 TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**

**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)

**127.00 $**  **32.43**

**$ 16.16** 

**$ 175.58** 

**$ 0.81** 

**$ 10.64** 

**$ 9.75** 

**$ 4.03** 

**$ 25.23** 

**$ 0.68** 

**$ 201.50** 

**$ -** 

**$ -** 

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### -

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**$ -** 

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**$ 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



# 18**Electrical Distribution and Electronic Control Sy stem** 

1 **01** 2 **03** 3 **04** 4 **06** 5 **07**

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem

End Item

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

**- $**  **-**

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**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)** 



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### 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 DESCRIPTIONItemSubsystem

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)** 



### - **$ -** 

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### ###### **32.43 $**  **16.16**

**$ 175.58** 

**$ 0.81** 

**$ 10.64** 

**$ 9.75** 

**$ 4.03** 

**$ 25.23** 

**$ 0.68** 

**$ 201.50** 

**$ -** 

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### 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 Sy stem** 

1 **01** 2 **03** 3 **04** 4 **06** 5 **07**

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem **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 -** 

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### 19 **0** 20 **0 -** 

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### 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 DESCRIPTIONItemSubsystem **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