### Page:1 of 6 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

0.541818182

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



## 021200 Transmission Cooling Subsystem

1 **00 Assembly of Cooling Subsystem**  **0.36 $** 

**-**

**$**

**-**

**$ 0.36** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 0.36** 

**$ Negligible Change** 



### 2 **01 Water Pumps**  **24.35 $**  **3.09**

**$ 4.49** 

**$ 31.93** 

**$** 

### 0.17

**$ 2.36** 

**$ 2.11** 

**$ 0.81** 

**$ 5.46** 

**$** 

### 0.08

**$ 37.47** 

**$ Engine Torque** 



### 3 **02 Thermostat Housings** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**



### -

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

**$**

**-**

**$**



### 4 **04 Heat Exchangers**  **4.80 $**  **8.09**

**$ 7.84** 

**$ 20.73** 

**$** 

### 0.18

**$ 2.69** 

**$ 2.19** 

**$ 0.58** 

**$ 5.63** 

**$** 

### 0.10

**$ 26.46** 

**$ Engine Torque** 



### 5 **05 Pressure Regulators** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

# SYSTEM & SUBSYSTEM DESCRIPTION

**Total Markup Cost**  **(Component/ Assembly)**  **Total**

**Packaging Cost**  **(Component / Assembly)** ItemSubsystem


### Sub-Subsystem Description **Scaling Parameter(s) Description Notes** 



# 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)** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM** 

# Technology **Level:** Parallel HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

# Study Case#: N0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

Material Deltas Base Based On Polar Moment of Inertia Calc's 35% Torque Reducion Results in 25% Material Reduction 22% Troque Reduction Results in 15% Material Reduction 46% Increase in Torque Results in a 28% Increase in Material

Burden Based on Stamping Circ. 35% Torque Reducion Results in 13.4% B urden 

### 6 **06 Expansion Tanks**  **2.19 $**  **1.46**

**$ 1.27** 

**$ 4.93** 

**$ 0.04** 

**$ 0.60** 

**$ 0.49** 

**$ 0.14** 

**$ 1.27** 

**$ 0.05** 

**$ 6.25** 

**$ Negligible Change** 



### 7 **65 Adapters** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 8 **70 Pipes, Hoses, Ducting**  **1.21 $**  **0.40**

**$ 0.29** 

**$ 1.89** 

**$** 

### 0.01

**$ 0.21** 

**$ 0.14** 

**$ 0.02** 

**$ 0.37** 

**$** 

### 0.02

**$ 2.28** 

**$ Negligible Change** 



### 9 **75 Brackets** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 10 **80 Boltings** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 11 **85 Sealing Elements** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 12 **90 Bearings Elements Misc** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 13 **95 Tools** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 14 **99 Miscellaneous** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0 **0 0** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0 **0 0** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0 **0 0** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0 **0 0** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0 **0 0** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 35% Torque Reducion Results in 13.4% B urden Reduction 22% Troque Reduction Results in 8% Burden Reduction 46% Increase in Torque Results in a 13.4% Increase in Material



### 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

0.541818182

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

# SYSTEM & SUBSYSTEM DESCRIPTION

**Total Markup Cost**  **(Component/ Assembly)**  **Total**

**Packaging Cost**  **(Component / Assembly)** ItemSubsystem


### Sub-Subsystem Description **Scaling Parameter(s) Description Notes** 



# 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)** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM** 

# Technology **Level:** Parallel HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

# Study Case#: N0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

**32.91 $**  **13.04**

**$ 13.89** 

**$ 59.84** 

**$ 0.40** 

**$ 5.85** 

**$ 4.93** 

**$ 1.55** 

**$ 12.74** 

**$ 0.24** 

**$ 72.82** 

**$**

**-**

**$** 

### SUBSYSTEM 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



## 021200 Transmission Cooling Subsystem

1 **00**

2 **01**

3 **02**

4 **04**

5 **05** 

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem 

### Scaling Factor

**Relative to Baseline**  **(Ford Fusion) Value**  **Scaling Factor Relative to**  **Baseline (Ford Fusion)**  **Value Scaling Factor**  **Relative to Baseline**  **(Ford Fusion) Value**  Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D Material

**0.36 $**  **0.36 $**  **0.36 $** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 0.36** 

**$**

**Multi 29.63** 

**$ Multi**  **32.77 $**  **Multi 46.16**  **$**



### -

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 24.35** 

**$**



### - **$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**Multi 23.60** 

**$ Multi**  **24.75 $**  **Multi 29.51**  **$** 

### 4.89

**$ 8.99** 

**$ 9.19** 

**$ 23.06** 

**$** 

### 0.19

**$ 2.92** 

**$ 2.38** 

**$ 0.64** 

**$ 6.14** 

**$**



### -

**$ 29.20** 

**$**

**-**

**$**

**-**

**$**

**-**

**$ (0.09)** 

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ Large Size Vehicle Segment**  **(e.g Ford Flex)** 

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

**Sub-Compact Vehicle Segment (e.g Ford Fiesta)**  **Small/Compact Vehicle Segment (e.g Ford Fusion)**  Manufacturing **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)**  **Tooling**

**(x1000) Investment** 

**(X1000)**



### 6 **06**

7 **65**

8 **70**

9 **75**

10 **80**

11 **85**

12 **90**

13 **95**

14 **99**

0 **0**

0 **0**

0 **0**

0 **0**

0 **0 6.25**  **$ 6.25**  **$ 6.25**  **$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 2.19** 

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**2.28 $**  **2.28 $**  **2.28 $** 



### -

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 1.21** 

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 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 

### Scaling Factor **Relative to Baseline**  **(Ford Fusion) Value**  **Scaling Factor Relative to**  **Baseline (Ford Fusion)**  **Value Scaling Factor**  **Relative to Baseline**  **(Ford Fusion) Value**  Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D Material **Large Size Vehicle Segment (e.g Ford Flex)**  

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

**Sub-Compact Vehicle Segment (e.g Ford Fiesta)**  **Small/Compact Vehicle Segment (e.g Ford Fusion)**  Manufacturing **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)**  **Tooling**

**(x1000) Investment** 

**(X1000)**



### 4.89 **$ 8.99** 

**$ 9.19** 

**$ 23.06** 

**$ 0.19** 

**$ 2.92** 

**$ 2.38** 

**$ 0.64** 

**$ 6.14** 

**$**

**-**

**$ 29.20** 

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 28.03

**$**

**62.12 $**  **66.41 $**  **84.56 $** 



### 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



## 021200 Transmission Cooling Subsystem

1 **00**

2 **01**

3 **02**

4 **04**

5 **05** 

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



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

**- $** 

**-**

**$ 0.36** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 0.36** 

**$ #REF!**  **#REF! #REF!** 

**3.09 $**  **4.49**

**$ 31.93** 

**$ 0.17** 

**$ 2.36** 

**$ 2.11** 

**$ 0.81** 

**$ 5.46** 

**$ 0.08** 

**$ 37.47** 

**$ #REF!**  **#REF! #REF!** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ #REF!**  **#REF! #REF!** 

**(0.90) $**  **(1.35)**

**$ (2.33)** 

**$ (0.02)** 

**$ (0.23)** 

**$ (0.19)** 

**$ (0.06)** 

**$ (0.50)** 

**$ 0.10** 

**$ (2.73)** 

**$ #REF!**  **#REF! #REF!** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ #REF!**  **#REF! #REF!**  

# 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**  **Investment(X1 000)**  **System ED&T/R&D**  **(x1000) Tooling** 

**(x1000)**



### 6 **06**

7 **65**

8 **70**

9 **75**

10 **80**

11 **85**

12 **90**

13 **95**

14 **99**

0 **0**

0 **0**

0 **0**

0 **0**

0 **0 1.46** 

**$ 1.27** 

**$ 4.93** 

**$ 0.04** 

**$ 0.60** 

**$ 0.49** 

**$ 0.14** 

**$ 1.27** 

**$ 0.05** 

**$ 6.25** 

**$ #REF!**  **#REF! #REF!** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ #REF!**  **#REF! #REF!** 

**0.40 $**  **0.29**

**$ 1.89** 

**$ 0.01** 

**$ 0.21** 

**$ 0.14** 

**$ 0.02** 

**$ 0.37** 

**$ 0.02** 

**$ 2.28** 

**$ #REF!**  **#REF! #REF!** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ #REF!**  **#REF! #REF!** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ #REF!**  **#REF! #REF!** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ #REF!**  **#REF! #REF!** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ #REF!**  **#REF! #REF!** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ #REF!**  **#REF! #REF!** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ #REF!**  **#REF! #REF!** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ #REF!**  **#REF! #REF!** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ #REF!**  **#REF! #REF!** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ #REF!**  **#REF! #REF!** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ #REF!**  **#REF! #REF!** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ #REF!**  **#REF! #REF!** 



### 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



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

# 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**  **Investment(X1 000)**  **System ED&T/R&D**  **(x1000) Tooling** 

**(x1000)**



### 4.06 **$ 4.70** 

**$ 36.78** 

**$ 0.21** 

**$ 2.93** 

**$ 2.55** 

**$ 0.91** 

**$ 6.60** 

**$ 0.24** 

**$ 43.62** 

**$ #REF!**  **#REF! #REF!** 



### 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



## 021200 Transmission Cooling Subsystem

1 **00 Assembly of Cooling Subsystem**  **0.36 $** 

**-**

**$**

**-**

**$ 0.36** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 0.36** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 2 **01 Water Pumps**  **24.35 $**  **3.09**

**$ 4.49** 

**$ 31.93** 

**$** 

### 0.17

**$ 2.36** 

**$ 2.11** 

**$ 0.81** 

**$ 5.46** 

**$** 

### 0.08

**$ 37.47** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 3 **02 Thermostat Housings** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**



### -

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 4 **04 Heat Exchangers**  **4.80 $**  **8.09**

**$ 7.84** 

**$ 20.73** 

**$** 

### 0.18

**$ 2.69** 

**$ 2.19** 

**$ 0.58** 

**$ 5.63** 

**$** 

### 0.10

**$ 26.46** 

**$**

**-**

**$**

**-**

**$**

**-**

**$** 

### 4.89

**$ 8.99** 

**$ 9.19** 

**$ 23.06** 

**$**



### 5 **05 Pressure Regulators** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)**  Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**ItemSubsystem 

### System **ED&T/R&D (x1000)**  

### Sub-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) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** **Technology Level:**  Parallel HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

# Study Case#: N0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

6 **06 Expansion Tanks**  **2.19 $**  **1.46**

**$ 1.27** 

**$ 4.93** 

**$ 0.04** 

**$ 0.60** 

**$ 0.49** 

**$ 0.14** 

**$ 1.27** 

**$ 0.05** 

**$ 6.25** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 7 **65 Adapters** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 8 **70 Pipes, Hoses, Ducting**  **1.21 $**  **0.40**

**$ 0.29** 

**$ 1.89** 

**$** 

### 0.01

**$ 0.21** 

**$ 0.14** 

**$ 0.02** 

**$ 0.37** 

**$** 

### 0.02

**$ 2.28** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 9 **75 Brackets** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 10 **80 Boltings** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 11 **85 Sealing Elements** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 12 **90 Bearings Elements Misc** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 13 **95 Tools** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 14 **99 Miscellaneous** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0 **0 0** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0 **0 0** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0 **0 0** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0 **0 0** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0 **0 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

Markup **Net Component/**  **Assembly Cost Impact to**  **OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)**  Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**ItemSubsystem 

### System **ED&T/R&D (x1000)**  

### Sub-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) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** **Technology Level:**  Parallel HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

# Study Case#: N0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)

**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** 

**$ SUBSYSTEM 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



## 021200 Transmission Cooling Subsystem

1 **00**

2 **01**

3 **02**

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

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 0.36** 

**$**

**-**

**$**

**-**

**$ 0.36** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 0.36** 

**$**

**-**

**$**

**-**

**$**



### - **$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 24.35** 

**$ 3.09** 

**$ 4.49** 

**$ 31.93** 

**$ 0.17** 

**$ 2.36** 

**$ 2.11** 

**$ 0.81** 

**$ 5.46** 

**$ 0.08** 

**$ 37.47** 

**$**

**-**

**$**

**-**

**$**



### - **$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0.19 **$ 2.92** 

**$ 2.38** 

**$ 0.64** 

**$ 6.14** 

**$**



### -

**$ 29.20** 

**$**

**-**

**$**

**-**

**$**

**-**

**$ (0.09)** 

**$ (0.90)** 

**$ (1.35)** 

**$ (2.33)** 

**$ (0.02)** 

**$ (0.23)** 

**$ (0.19)** 

**$ (0.06)** 

**$ (0.50)** 

**$ 0.10** 

**$ (2.73)** 

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$** 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)** 

# 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**  

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

6 **06**

7 **65**

8 **70**

9 **75**

10 **80**

11 **85**

12 **90**

13 **95**

14 **99**

0 **0**

0 **0**

0 **0**

0 **0**

0 **0 -** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 2.19** 

**$ 1.46** 

**$ 1.27** 

**$ 4.93** 

**$ 0.04** 

**$ 0.60** 

**$ 0.49** 

**$ 0.14** 

**$ 1.27** 

**$ 0.05** 

**$ 6.25** 

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - **$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### -

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 1.21** 

**$ 0.40** 

**$ 0.29** 

**$ 1.89** 

**$ 0.01** 

**$ 0.21** 

**$ 0.14** 

**$ 0.02** 

**$ 0.37** 

**$ 0.02** 

**$ 2.28** 

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 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

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

# 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**  

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

**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** 

**$**

**-**

**$**

**-**

**$**



### 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



## 021200 Transmission Cooling Subsystem

1 **00**

2 **01**

3 **02**

4 **04**

5 **05**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

**- $** 

**- $** 

**- $** 

**- $** 

**- $**  **Investment(X1 000)** 



### 6 **06**

7 **65**

8 **70**

9 **75**

10 **80**

11 **85**

12 **90**

13 **95**

14 **99**

0 **0**

0 **0**

0 **0**

0 **0**

0 **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

**Investment(X1 000)** 

**- $** 



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

# 0



# 021200 Transmission Cooling Subsy **stem**

1 **00**

A H Trans Vehicle Mounting Hardware 02 # 00

- N0502

- 01
02 # 00

- N0502

- **
2 **01**

A H Aux Pump Heater Circ Pump Asm 02 # 01

- N0502

- 01
02 # 01

- N0502

-  As**  **sembly of Cooling Subsystem**

**Water Pumps**ItemSubsystemSub-SubsystemAssemblySubassemblyComponent 

# Name/Description Part Number 

# NEW TECHNOLOGY GENERA **L PA RT INFORMA**  **TION: 2010 Ford Fusion, 2.5L A**  **tkinson Cy cle, I4, 156hp (191 Net),**  **(Motor 60kW, Battery**

**275V, Nominal Pack Capacity 5.5A**  **h, 1.51kWh) Technology**  **Level: Parallel HEV Technology Vehicle Class: Mid to Large Size Passenger Vehicle, 4** 

**- 6 Passengers**  **Study Case#: N0502 (N=New, B=Base, ) 05=Technology**  **Package, 02=Vehicle Class**

02 # 01

- N0502

- **
3 **02** 02 # 02

- N0502

- 01
02 # 02

- N0502

- **
4 **04**

A H - Cooler Asm Trans DC DC Mod C 02 # 04

- N0502

- 01
02 # 04

- N0502

- ** 5 **05** 02 # 05

- N0502

- 01
02 # 05

- N0502

- **
6 **06**

A H Bottle Asm, Trans Coolant A 02 # 06

- N0502

- 01
02 # 06

- N0502

- **
7 **65** 02 # 65

- N0502

- 01
02 # 65

- N0502

- **
9 **70**

A H - Trans Cooler Line Asm D 02 # 70

- N0502

- 01
02 # 70

- N0502

-  Pipes, Hoses, Ducting**  **Ad apters**  **Thermostat Housings**

**Heat Exchangers**

**Pressure Regulators**

**Expansion Tanks**

# 10 **75** 02 # 75

- N0502

- 01
02 # 75

- N0502

- **
11 **80** 02 # 80

- N0502

- 01
02 # 80

- N0502

- **
12 **85** 02 # 85

- N0502

- 01
02 # 85

- N0502

- **
13 **90** 02 # 90

- N0502

- 01
02 # 90

- N0502

- **
14 **95** 02 # 95

- N0502

- 01
02 # 95

- N0502

- ** 15 **99** 02 # 99

- N0502

- 01
02 # 99

- N0502

- **

**NOTES:**



# 1. **Bearings Elements Misc**

**= A**

**highlighted Sub-subsystem, A ssembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of**  **Miscellaneous Tools**  **Sealing Elements Brackets** 

**Boltings**



# 1. **= A**

**highlighted Sub-subsystem, A ssembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of**  **the competing technology**

# Material Labor Burden

**- $** 

**-**

**$**

**-**

**$**

**0.36 $** 

**-**

**$**

**-**

**$** 

# 1 Full 1 0.36 $

**-**

**$**

**-**

**$**

**24.35 $**  **3.09**

**$ 4.49** 

**$** 

# 1 Full 1 24.35 $ 3.09

$ 4.49

$ ManufacturingQTY/Subsystem 

# Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) Notes 

# NEW TECHNOLOGY PA **CKA GE QUOTE** 

**PA RA**  **METERS 6 Passengers**  **Study Case#: N0502 (N=New, B=Base, ) 05=Technology**  **Package, 02=Vehicle Class**

- $

-

$

-

$



# 4.80 $ 8.09

$ 7.84

$ 1 Full 1 

# 4.80 $ 8.09

$ 7.84

$

- $

-

$

-

$

**2.19 $**  **1.46**

**$ 1.27** 

**$** 

# 1 Full 1 2.19 $ 1.46

$ 1.27

$

**- $** 

**-**

**$**

**-**

**$**



# 1.21 **$ 0.40** 

**$ 0.29** 

**$** 1 Full 1 

# 1.21 $ 0.40

$ 0.29

$

# - $

-

$

-

$

- $

-

$

-

$

- $

-

$

-

$

- $

-

$

-

$

- $

-

$

-

$

- $

-

$

-

$

32.91 $ 13.04

$ 13.89

$

**= A**

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

# End Item Scrap SG&A Profit ED&T-R&D

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**0.36 $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 0.36** 

**$**
**0.36 $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 0.36** 

**$**

**31.93 $**  **0.17**

**$ 2.36** 

**$ 2.11** 

**$ 0.81** 

**$ 5.46** 

**$ 0.08** 

**$ 37.47** 

**$**
31.93 $ 0.17

$ 2.36

$ 2.11

$ 0.81

$ 5.46

$ 0.08

$ 37.47

$ **Total Packaging**  **Cost (Component**  **/ Assembly )**  **Net**

**Component/ Assembly**  **Cost Impact to OEM**  **Total Manufacturing**  **Cost (Component/**  **Assembly )**  **Total Markup Cost**  **(Component/ Assembly**  **)** 

# NEW TECHNOLOGY PA **CKA GE COST INFORMA**  **TION**

Markup



# - **$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**- $** 

**- $** 

-

$

**-**

**$**
**20.73 $**  0.18

$ 2.69

$ 2.19

$ 0.58

$ **5.63**

**$** 0.10

$ **26.46**

**$ 20.73**  **$** 0.18

$ 2.69

$ 2.19

$ 0.58

$ **5.63**

**$** 0.10

$ **26.46**

**$**

**- $** 

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**4.93 $**  **0.04**

**$ 0.60** 

**$ 0.49** 

**$ 0.14** 

**$ 1.27** 

**$ 0.05** 

**$ 6.25** 

**$**
**4.93 $**  0.04

$ 0.60

$ 0.49

$ 0.14

$ **1.27**

**$ 0.05** 

**$ 6.25** 

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



# 1.89 **$ 0.01** 

**$ 0.21** 

**$ 0.14** 

**$ 0.02** 

**$ 0.37** 

**$ 0.02** 

**$ 2.28** 

**$ 1.89**  **$** 0.01

$ 0.21

$ 0.14

$ 0.02

$ **0.37**

**$** 0.02

$ **2.28**

**$**

# -

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**- $** 

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**- $** 

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**- $** 

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**- $** 

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**- $** 

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**59.84 $**  0.40

$ 5.85

$ 4.93

$ 1.55

$ **12.74**

**$** 0.24

$ **72.82**

**$**

# -

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$ Sy**  **stem ED&T/R&D**  **(x1000) Investment**  **(X1000) Tooling**  **(x1000)**

**- $** 

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

# -

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**



# - **$**

**-**

**$**

**-**

**$**

### Page: 1 of 12 

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

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: B0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM Assembly, Mark-up Covered by ICM** 

## System Description: **2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT** 

## Annual Component Volume: Shipping Method: **Component Description: H Trans Vehicle Mounting Hardware**  

## Part Number: **021200-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

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

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

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

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

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

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
5 **0 #####**  **0 1**  **1.1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### Costs Broken Out Into Categories with Quantity per Assembly Taken into Account **TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

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

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
3 **0 #####**  **0 7**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 12 

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

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: B0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM Assembly, Mark-up Covered by ICM** 

## System Description: **2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT** 

## Annual Component Volume: Shipping Method: **Component Description: H Trans Vehicle Mounting Hardware**  

## Part Number: **021200-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

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

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

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### C 

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

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### D 

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

**Price/ Unit**  **Purchase**

**Price Net, PIA**  **Purchase**

**Price Net, End Item** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 12 

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

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: B0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM Assembly, Mark-up Covered by ICM** 

## System Description: **2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT** 

## Annual Component Volume: Shipping Method: **Component Description: H Trans Vehicle Mounting Hardware**  

## Part Number: **021200-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

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

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

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

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

2 H Bolt Trans Coolant Bottle 011404-N0502-02 **1** S **$0.00** $0.06 **$0.00 $0.06**  **$0.06**
3 H Nut Trans Coolant Bottle 011404-N0502-03 **1** S **$0.00** $0.06 **$0.00 $0.06**  **$0.06**

4 H Bolt, Trans Coolant Pump 011404-N0502-04 **2** S **$0.00** $0.06 **$0.00 $0.12**  **$0.12**

5 H Bolt, Trans Cooler to FEM 011404-N0502-05 **1** S **$0.00** $0.06 **$0.00 $0.06**  **$0.06**

4 H Bolt, Trans Cooler to FEM 011404-N0502-06 **1** S **$0.00** $0.06 **$0.00 $0.06**  **$0.06**

7 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
10 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

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

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

Assembly.

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

- Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark

- up Calculations.

"Alpha

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

12 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

22 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
23 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

24 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
25 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
26 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

27 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
28 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
29 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
30 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$0.36**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$0.36**

**T1 or OEM Total Manufacturing Cost: $0.36**  **$0.00 $0.00**  **$0.36 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.36**

**T1 or OEM Mark-Up Rates:**

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

----- ----- ----- **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**
**Base Cost Impact to Vehicle: $0.36**  **$0.00 $0.00**  **$0.36 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.36 $0**  **$0 Packaging Cost:**  **$0.00**

**3 1** 



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

**Packaging Cost: $0.00**  **Net Cost Impact to Vehicle: $0.36** 



### Reference Packaging Database for Additional Information Maximum Pallet Stack Height = 100" Pallet Options



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 4 of 12 

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

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: B0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **OEM Assembly, Mark-up Covered by ICM** 

## System Description: **2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT** 

## Annual Component Volume: Shipping Method: **Component Description: H Trans Vehicle Mounting Hardware**  

## Part Number: **021200-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

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

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

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

**Packaging Cost per**  **Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

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



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

**Packaging Cost per**  **Piece Tier Pad**  **Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging Price Per**  **Other #1**

**Pads Pallet/Rack**  **Other #2**

**Packaging Price Per**  **Other #2**

**Pads Pallet/Rack**  **Other #3**

**Packaging, Price Per**  **Other #3**

**Pads Pallet/Rack** 



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

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.) Assume Plastic Returnable Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote **Expendable Packaging in Piece Cost: $0.00**  $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 

### Packaging Cost Total: **$0.000** 

### Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base
Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 5 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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



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

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

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

- - - - **1.0 1.0** 

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

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

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

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

- - - - **1.1 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**



## Purchase Part - High Impact Item (Full Cost Mapping) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

- - - - **1.0 1.0** 

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

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

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

- - - - **1.0 7.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

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

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

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

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

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

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

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

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

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

- - - - **1.0 1.0** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

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

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

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

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

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

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

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

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

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

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

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

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

- - - - **1.0 1.0** 



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

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

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

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

- - - - **1.0 1.0** 

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

- - - - **1.0 1.0** 



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

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

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

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

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

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

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

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

- - - - **1.0 1.0** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 7 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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

H Bolt Trans Coolant Bottle 011404-N0502-02 H Nut Trans Coolant Bottle 011404-N0502-03 H Bolt, Trans Coolant Pump 011404-N0502-04 H Bolt, Trans Cooler to FEM 011404-N0502-05 H Bolt, Trans Cooler to FEM 011404-N0502-06 

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

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$0.00 $0.06**  **$0.06 $0.12**  **$0.06 $0.06**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up**  **Total**
**$0.00 $0.00**  **$0.36 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$0.36 2** 



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



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 8 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 9 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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

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

-

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

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

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

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

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

-



## Purchase Part - High Impact Item (Full Cost Mapping) **#DIV/0! #DIV/0!** 

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

-

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

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

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

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

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

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

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

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

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

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

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

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

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

-



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 10 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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

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

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

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

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

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

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

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

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

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

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

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

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

-



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

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

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

-

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

-



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **#DIV/0! #DIV/0!** 

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

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

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

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

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

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

-



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 11 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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

H Bolt Trans Coolant Bottle 011404-N0502-02 H Nut Trans Coolant Bottle 011404-N0502-03 H Bolt, Trans Coolant Pump 011404-N0502-04 H Bolt, Trans Cooler to FEM 011404-N0502-05 H Bolt, Trans Cooler to FEM 011404-N0502-06**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 12 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 12 

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

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT** 

## Annual Component Volume: Shipping Method: **Component Description: H Bottle Asm, Trans Coolant A**  

## Part Number: **021306-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

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

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

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

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

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

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
5 **0 #####**  **0 1**  **1.1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### 9,574

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000** 

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

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

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

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

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

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

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

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
3 **0 #####**  **0 1**  **1** 0.711 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
4 H Isolation Ring, Mount, Coolant Pump 021306-N0502-19 **1** Mold T2/T3 Inject. Mold, SSLC Thermoset-SBR Mold/Cast/Sinter Operator Inject. Mold, SS **1091 1**  **1 1**  0.049 **$1.32 $41.48**  **$16.39 $16.39**  **$0.06 $0.04**  **$0.02 $0.12**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.13 $0.13**  **$0.06**
5 H Clamp, Mount, Coolant Pump 021306-N0502-20 **1** Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **3000 1**  **1 1**  0.066 **$1.74 $41.48**  **$16.39 $16.39**  **$0.11 $0.01**  **$0.01 $0.13**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.15 $0.15**  **$0.11**

6 H Bracket, Mount, Coolant Pump 021306-N0502-21 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **277 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.07**  **$0.05 $0.12**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.14 $0.14**  **$0.00**

7 021306-N0502-21A **1** Paint T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **152 0.5**  **3 1**  0.000 **$0.00 $38.55**  **$15.00 $45.00**  **$0.00 $0.13**  **$0.30 $0.42**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.47 $0.47**  **$0.00**

8 021306-N0502-21B **1** Wash T2/T3 Mech. Assembly, SSLC LC-GSteel-1000S, Coil General Assembly Washing Equipment, LC **277 0.25**  **1 1**  0.000 **$0.48 $38.55**  **$10.75 $10.75**  **$0.00 $0.03**  **$0.04 $0.07**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.08 $0.08**  **$0.00**

9 021306-N0502-21C **1** Stamp T2/T3 Stamp/Form, MSMC LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **5143 0.5**  **1 1**  0.303 **$0.48 $42.73**  **$15.50 $15.50**  **$0.15 $0.00**  **$0.00 $0.15**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.02**  **$0.17 $0.17**  **$0.15**
10 H Clamp On Christmas Tree Clip 021306-N0502-22 **1** Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **3273 1**  **1 1**  0.026 **$1.74 $41.48**  **$16.39 $16.39**  **$0.05 $0.01**  **$0.01 $0.06**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.07 $0.07**  **$0.05**



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 12 

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

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT** 

## Annual Component Volume: Shipping Method: **Component Description: H Bottle Asm, Trans Coolant A**  

## Part Number: **021306-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

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

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

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000** 

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

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

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

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

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

11 H Coolant Line, Pump to E Motor 021306-N0502-23 **1** Extrude T2/T3 Comp./Ext. Mold, SSLC Thermoset-SBR Extruding/Drawing Operator Extrusion Molding, NR, SS **522 1**  **1 1**  0.340 **$1.32 $56.05**  **$35.94 $35.94**  **$0.45 $0.11**  **$0.07 $0.63**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.06**  **$0.69 $0.69**  **$0.45**

12 H Coolant Line, DC-DC to Pump 021306-N0502-24 **1** Extrude T2/T3 Comp./Ext. Mold, SSLC Thermoset-SBR Extruding/Drawing Operator Extrusion Molding, NR, SS **225 1**  **1 1**  0.502 **$1.32 $56.05**  **$35.94 $35.94**  **$0.66 $0.25**  **$0.16 $1.07**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.11**  **$1.18 $1.18**  **$0.66**

13 H Coolant Line Asm, DC-DC to Pump 021306-N0502-25 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **174 1.5**  **3 1**  0.000 **$0.00 $38.55**  **$15.00 $45.00**  **$0.00 $0.33**  **$0.26 $0.59**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.06**  **$0.65 $0.65**  **$0.00**

14 H Coolant Line Asm, Pump to E motor 021306-N0502-26 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **138 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.14**  **$0.11 $0.25**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.27 $0.27**  **$0.00**

15 H Trans Coolant Pump w/Mount 021306-N0502-27 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **148 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.13**  **$0.10 $0.23**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.26 $0.26**  **$0.00**

16 H Trans Coolant Pump Sub Asm. 021306-N0502-28 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **189 1**  **2 1**  0.000 **$0.00 $38.55**  **$15.00 $30.00**  **$0.00 $0.20**  **$0.16 $0.36**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.40 $0.40**  **$0.00**

17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### C 

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

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 12 

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

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT** 

## Annual Component Volume: Shipping Method: **Component Description: H Bottle Asm, Trans Coolant A**  

## Part Number: **021306-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

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

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

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000** 

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

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

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

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

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

29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### D 

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

**Price/ Unit**  **Purchase**

**Price Net, PIA**  **Purchase**

**Price Net, End Item** 

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

2 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
3 H Sheath, (15/16"), Bottle to Trans Hose 021306-N0502-15 **1** S **$0.00** $0.18 **$0.00 $0.18**  **$0.18**

4 H Hose Clamp, Medium (24mm) 021306-N0502-16 **1** S **$0.00** $0.22 **$0.00 $0.22**  **$0.22**

5 H Hose Clamp, Medium (22mm) 021306-N0502-17 **1** S **$0.00** $0.21 **$0.00 $0.21**  **$0.21**
6 H Label, Trans Cooler Bottle 021306-N0502-18 **1** S **$0.00** $0.10 **$0.00 $0.10**  **$0.10** 

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

Assembly.

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

- Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for 6 H Label, Trans Cooler Bottle 021306-N0502-18 **1** S **$0.00** $0.10 **$0.00 $0.10**  **$0.10**

7 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
10 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

12 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

22 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
23 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

24 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
25 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
26 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

27 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
28 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
29 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
30 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$2.19**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total $5.37**  

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

- up Calculations.

"Alpha

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

**1 Material**  **Labor Burden**  **TMC Scrap**  **SG&A Profit**  **ED&T Mark-up**  **$5.37**

**T1 or OEM Total Manufacturing Cost: $2.19**  **$1.46 $1.27**  **$4.93 $0.01**  **$0.25 $0.17**  **$0.00 $0.44**  **$5.37**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% **(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.03 $0.35**  **$0.32 $0.13**  **$0.83**
**Base Cost Impact to Vehicle: $2.19**  **$1.46 $1.27**  **$4.93 $0.04**  **$0.60 $0.49**  **$0.14 $1.27**  **$6.20 $0**  **$0 Packaging Cost:**  **$0.05 Net Cost Impact to Vehicle:**  **$6.25 3**  **1**



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



### Reference Packaging Database for Additional Information Maximum Pallet Stack Height = 100" 

### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 4 of 12 

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

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT** 

## Annual Component Volume: Shipping Method: **Component Description: H Bottle Asm, Trans Coolant A**  

## Part Number: **021306-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

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

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

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000** 

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

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

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

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

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

**Packaging Cost per**  **Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

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



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

**Packaging Cost per**  **Piece Tier Pad**  **Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging Price Per**  **Other #1**

**Pads Pallet/Rack**  **Other #2**

**Packaging Price Per**  **Other #2**

**Pads Pallet/Rack**  **Other #3**

**Packaging, Price Per**  **Other #3**

**Pads Pallet/Rack**  

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.) Assume Plastic Returnable Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. **Expendable Packaging in Piece Cost: $0.00**  $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 

### Packaging Cost Total: **$0.000** 

### Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base
Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 5 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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



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

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

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

- - - - **1.0 1.0** 

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

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

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

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

- - - - **1.1 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**



## Purchase Part - High Impact Item (Full Cost Mapping) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

- - - - **1.0 1.0** 

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

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

- - - - **1.0 1.0** 

H Isolation Ring, Mount, Coolant Pump 021306-N0502-19 H Clamp, Mount, Coolant Pump 021306-N0502-20

H Bracket, Mount, Coolant Pump 021306-N0502-21

021306-N0502-21A

021306-N0502-21B

021306-N0502-21C H Clamp On Christmas Tree Clip 021306-N0502-22 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.04 $0.02**  **$0.12 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  55-150 ton , 12 cavity mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 3.3 1 12 39.6 **1.0 1.0**  **$0.01 $0.01**  **$0.13 $0.00**  **$0.01 $0.01**  **$0.00 $0.01**  55-150 ton , 14 cavity mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1.2 1 14 16.8 **1.0 1.0** 

**$0.07 $0.05**  **$0.12 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  Peal offf backing and press foam pad to bracket **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 3 1 13 **1.00 1.0** 

**$0.13 $0.30**  **$0.42 $0.00**  **$0.03 $0.02**  **$0.00 $0.04**  Dipped/air dryed **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 71 1 1 71 **1.0 3.0** 

**$0.03 $0.04**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.01** 
Batch Wash **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.00 $0.00**  **$0.15 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  0-60 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.7 1 1 0.7 **1.0 1.0**  **$0.01 $0.01**  **$0.06 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  55-150 ton , 14 cavity mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1.1 1 14 15.4 **1.0 1.0** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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

H Coolant Line, Pump to E Motor 021306-N0502-23

H Coolant Line, DC-DC to Pump 021306-N0502-24

H Coolant Line Asm, DC-DC to Pump 021306-N0502-25

H Coolant Line Asm, Pump to E motor 021306-N0502-26

H Trans Coolant Pump w/Mount 021306-N0502-27

H Trans Coolant Pump Sub Asm. 021306-N0502-28 

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

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.11 $0.07**  **$0.63 $0.00**  **$0.04 $0.03**  **$0.00 $0.06**  Extrude, autoclave on mandrel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 6.9 1 1 6.9 **1.0 1.0** 

**$0.25 $0.16**  **$1.07 $0.00**  **$0.06 $0.04**  **$0.00 $0.11**  Extrude, autoclave on mandrel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 16 1 1 16 **1.0 1.0** 

**$0.33 $0.26**  **$0.59 $0.00**  **$0.04 $0.02**  **$0.00 $0.06**  Slip on sheath to coolant line and add clamps. Attach strap on hose clip and zip tie - trim to length. Add clamp on xmas tree to asm. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 62 4 1 62 **1.0 3.0** 

**$0.14 $0.11**  **$0.25 $0.00**  **$0.01 $0.01**  **$0.00 $0.03**  Attach clips to hose **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 26 2 1 26 **1.0 1.0** 

**$0.13 $0.10**  **$0.23 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  Place isolation ring onto trans coolant pump. Position clamp and bracket and snap onto trans coolant
pump **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 24.4 3 1 24.4 **1.0 1.0** 

**$0.20 $0.16**  **$0.36 $0.00**  **$0.02 $0.01**  **$0.00 $0.04**  Clamp coolant lines to trans coolant pump **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 38 2 1 38 **1.0 2.0** 



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

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

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

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

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

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

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

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

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

- - - - **1.0 1.0** 

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

- - - - **1.0 1.0** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 7 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

H Sheath, (15/16"), Bottle to Trans Hose 021306-N0502-15 H Hose Clamp, Medium (24mm) 021306-N0502-16 H Hose Clamp, Medium (22mm) 021306-N0502-17 H Label, Trans Cooler Bottle 021306-N0502-18 

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

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

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

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

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.18 $0.22**  **$0.21 $0.10**  H Label, Trans Cooler Bottle 021306-N0502-18 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up**  **Total**
**$1.46 $1.27**  **$4.93 $0.01**  **$0.25 $0.17**  **$0.00 $0.44** 

**$5.37 2** 



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



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 8 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 9 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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

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

-

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

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

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

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

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

-



## Purchase Part - High Impact Item (Full Cost Mapping) **#DIV/0! #DIV/0!** 

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

-

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

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

-

H Isolation Ring, Mount, Coolant Pump 021306-N0502-19 H Clamp, Mount, Coolant Pump 021306-N0502-20

H Bracket, Mount, Coolant Pump 021306-N0502-21

021306-N0502-21A

021306-N0502-21B

021306-N0502-21C H Clamp On Christmas Tree Clip 021306-N0502-22 **#DIV/0! #DIV/0!** 

- **1091 3.30**  1.00
**3000 1.20**  1.00

**277 13.00**  0.50

**152 23.67**  0.50

**277 13.00**  0.25

**5143 0.70**  0.50
**3273 1.10**  1.00



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 10 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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

H Coolant Line, Pump to E Motor 021306-N0502-23

H Coolant Line, DC-DC to Pump 021306-N0502-24

H Coolant Line Asm, DC-DC to Pump 021306-N0502-25

H Coolant Line Asm, Pump to E motor 021306-N0502-26

H Trans Coolant Pump w/Mount 021306-N0502-27

H Trans Coolant Pump Sub Asm. 021306-N0502-28**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**522 6.90**  1.00

**225 16.00**  1.00

**174 20.67**  1.50

**138 26.00**  0.50

**148 24.40**  0.50

**189 19.00**  1.00



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

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

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

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

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

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

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

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

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

-

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

-



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 11 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

H Sheath, (15/16"), Bottle to Trans Hose 021306-N0502-15 H Hose Clamp, Medium (24mm) 021306-N0502-16 H Hose Clamp, Medium (22mm) 021306-N0502-17 H Label, Trans Cooler Bottle 021306-N0502-18**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

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

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

-

H Label, Trans Cooler Bottle 021306-N0502-18



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 12 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 12 

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

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Aux Pump Heater Circ Pump Asm**  

## Part Number: **021301-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

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

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

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

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

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

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
5 **0 #####**  **0 1**  **1.1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### Costs Broken Out Into Categories with Quantity per Assembly Taken into Account **TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

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

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
2 H Isolation Ring, Mount, Coolant Pump 021301-N0502-19 **1** Mold T2/T3 Inject. Mold, SSLC Thermoset-SBR Mold/Cast/Sinter Operator Inject. Mold, SS **1091 1**  **1 1**  0.049 **$1.32 $41.48**  **$16.39 $16.39**  **$0.06 $0.04**  **$0.02 $0.12**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.13 $0.13**  **$0.06** Nylon66, Inject. Inject. Mold, SS 3 H Clamp, Mount, Coolant Pump 021301-N0502-20 **1** Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **3000 1**  **1 1**  0.066 **$1.74 $41.48**  **$16.39 $16.39**  **$0.11 $0.01**  **$0.01 $0.13**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.15 $0.15**  **$0.11**

4 H Bracket, Mount, Coolant Pump 021301-N0502-21 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **277 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.07**  **$0.05 $0.12**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.14 $0.14**  **$0.00**

5 021301-N0502-21A **1** Paint T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **152 0.5**  **3 1**  0.000 **$0.00 $38.55**  **$15.00 $45.00**  **$0.00 $0.13**  **$0.30 $0.42**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.47 $0.47**  **$0.00**

6 021301-N0502-21B **1** Wash T2/T3 Mech. Assembly, SSLC LC-GSteel-1000S, Coil General Assembly Washing Equipment, LC **277 0.25**  **1 1**  0.000 **$0.48 $38.55**  **$10.75 $10.75**  **$0.00 $0.03**  **$0.04 $0.07**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.08 $0.08**  **$0.00**

7 021301-N0502-21C **1** Stamp T2/T3 Stamp/Form, MSMC LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **5143 0.5**  **1 1**  0.303 **$0.48 $42.73**  **$15.50 $15.50**  **$0.15 $0.00**  **$0.00 $0.15**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.02**  **$0.17 $0.17**  **$0.15**
8 H Clamp On Christmas Tree Clip 021301-N0502-22 **1** Mold T2/T3 Inject. Mold, SSLC Nylon66, Inject. Mold/Cast/Sinter Operator Inject. Mold, SS **3273 1**  **1 1**  0.026 **$1.74 $41.48**  **$16.39 $16.39**  **$0.05 $0.01**  **$0.01 $0.06**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.07 $0.07**  **$0.05**

9 H Coolant Line, Pump to E Motor 021301-N0502-23 **1** Extrude T2/T3 Comp./Ext. Mold, SSLC Thermoset-SBR Extruding/Drawing Operator Extrusion Molding, NR, SS **522 1**  **1 1**  0.340 **$1.32 $56.05**  **$35.94 $35.94**  **$0.45 $0.11**  **$0.07 $0.63**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.06**  **$0.69 $0.69**  **$0.45**



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 12 

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

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Aux Pump Heater Circ Pump Asm**  

## Part Number: **021301-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

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

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

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

10 H Coolant Line, DC-DC to Pump 021301-N0502-24 **1** Extrude T2/T3 Comp./Ext. Mold, SSLC Thermoset-SBR Extruding/Drawing Operator Extrusion Molding, NR, SS **225 1**  **1 1**  0.502 **$1.32 $56.05**  **$35.94 $35.94**  **$0.66 $0.25**  **$0.16 $1.07**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.11**  **$1.18 $1.18**  **$0.66**

11 H Coolant Line Asm, DC-DC to Pump 021301-N0502-25 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **174 1.5**  **3 1**  0.000 **$0.00 $38.55**  **$15.00 $45.00**  **$0.00 $0.33**  **$0.26 $0.59**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.06**  **$0.65 $0.65**  **$0.00**

12 H Coolant Line Asm, Pump to E motor 021301-N0502-26 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **138 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.14**  **$0.11 $0.25**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.27 $0.27**  **$0.00**

13 H Trans Coolant Pump w/Mount 021301-N0502-27 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **148 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.13**  **$0.10 $0.23**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.26 $0.26**  **$0.00**

14 H Trans Coolant Pump Sub Asm. 021301-N0502-28 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **189 1**  **2 1**  0.000 **$0.00 $38.55**  **$15.00 $30.00**  **$0.00 $0.20**  **$0.16 $0.36**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.40 $0.40**  **$0.00**

15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### C 

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

1 1A H Aux Heater Cir Pump 021301-N0502-02 **1 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **$20.85 $1.63**  **$3.22 $25.70**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$25.70 $25.70**  **$20.85**
2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### D 

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

**Price/ Unit**  **Purchase**

**Price Net, PIA**  **Purchase**

**Price Net, End Item** 

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

2 H Foam Pad, Self Stick, Pump Bracket 021301-N0502-29 **1** S **$0.00** $0.01 **$0.00 $0.01**  **$0.01**
3 H Hose Clamp, Medium (27mm) 021301-N0502-30 **2** S **$0.00** $0.23 **$0.00 $0.46**  **$0.46**

4 H Sheath, (15/16"), Pump to Dc-Dc Module 021301-N0502-31 **1** S **$0.00** $1.19 **$0.00 $1.19**  **$1.19**

5 H Hose Clamp, Medium (27mm) 021301-N0502-32 **1** S **$0.00** $0.23 **$0.00 $0.23**  **$0.23**

4 H Strap On Hose Clip (#7) 021301-N0502-33 **1** S **$0.00** $0.04 **$0.00 $0.04**  **$0.04**

7 H Clamp On Christmas Tree Clip 021301-N0502-34 **1** S **$0.00** $0.08 **$0.00 $0.08**  **$0.08**
8 H Zip Tie 021301-N0502-35 **1** S **$0.00** $0.01 **$0.00 $0.01**  **$0.01**
9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

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

Assembly.

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

- Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark

- up Calculations.

"Alpha

- Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly. Imported detailed cost analysis from Mini Cooper Turbo afterrun pump

- increased material pricing by x1.5 to account for larger pump size.

9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
10 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

11 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
12 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### Supplier for Subassembly.



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 12 

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

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Aux Pump Heater Circ Pump Asm**  

## Part Number: **021301-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

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

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

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

21 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
22 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
23 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
24 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
25 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
26 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
27 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
28 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
29 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
30 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$24.35**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$32.37**

**T1 or OEM Total Manufacturing Cost: $24.35**  **$3.09 $4.49**  **$31.93 $0.01**  **$0.25 $0.17**  **$0.00 $0.44**  **$32.37**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% **(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.16 $2.10**  **$1.94 $0.81**  **$5.02**
**Base Cost Impact to Vehicle: $24.35**  **$3.09 $4.49**  **$31.93 $0.17**  **$2.36 $2.11**  **$0.81 $5.46**  **$37.39 $0**  **$0 Packaging Cost:**  **$0.08 Net Cost Impact to Vehicle:**  **$37.47**

**Packaging Cost per**  **Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

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



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

**Packaging Cost per**  **Piece Tier Pad**  **Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging Price Per**  **Other #1**

**Pads Pallet/Rack**  **Other #2**

**Packaging Price Per**  **Other #2**

**Pads Pallet/Rack**  **Other #3**

**Packaging, Price Per**  **Other #3**

**Pads Pallet/Rack** 



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

### Packaging Cost Total: **$0.000** 

### PACKAGING CALCULATIONS: Packaging Type: Specialized Racking/Containers (Estimate $0.12/part) Part Size: Parts/Layer: Number of Layers: **3 1** 



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



### Reference Packaging Database for Additional Information Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.) Assume Plastic Returnable Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base
Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 4 of 12 

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

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: H Aux Pump Heater Circ Pump Asm**  

## Part Number: **021301-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

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

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

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 5 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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



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

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

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

- - - - **1.0 1.0** 

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

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

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

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

- - - - **1.1 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**



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

H Isolation Ring, Mount, Coolant Pump 021301-N0502-19 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0**  **$0.04 $0.02**  **$0.12 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  55-150 ton , 12 cavity mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 3.3 1 12 39.6 **1.0 1.0**  H Clamp, Mount, Coolant Pump 021301-N0502-20

H Bracket, Mount, Coolant Pump 021301-N0502-21

021301-N0502-21A

021301-N0502-21B

021301-N0502-21C H Clamp On Christmas Tree Clip 021301-N0502-22

H Coolant Line, Pump to E Motor 021301-N0502-23 **$0.01 $0.01**  **$0.13 $0.00**  **$0.01 $0.01**  **$0.00 $0.01**  55-150 ton , 14 cavity mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1.2 1 14 16.8 **1.0 1.0** 

**$0.07 $0.05**  **$0.12 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  Peal offf backing and press foam pad to bracket **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 3 1 13 **1.00 1.0** 

**$0.13 $0.30**  **$0.42 $0.00**  **$0.03 $0.02**  **$0.00 $0.04**  Dipped/air dryed **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 71 1 1 71 **1.0 3.0** 

**$0.03 $0.04**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.01** 
Batch Wash **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 1.0** 

**$0.00 $0.00**  **$0.15 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  0-60 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.7 1 1 0.7 **1.0 1.0**  **$0.01 $0.01**  **$0.06 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  55-150 ton , 14 cavity mold **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1.1 1 14 15.4 **1.0 1.0** 

**$0.11 $0.07**  **$0.63 $0.00**  **$0.04 $0.03**  **$0.00 $0.06**  Extrude, autoclave on mandrel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 6.9 1 1 6.9 **1.0 1.0** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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

H Coolant Line, DC-DC to Pump 021301-N0502-24

H Coolant Line Asm, DC-DC to Pump 021301-N0502-25

H Coolant Line Asm, Pump to E motor 021301-N0502-26

H Trans Coolant Pump w/Mount 021301-N0502-27

H Trans Coolant Pump Sub Asm. 021301-N0502-28 

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

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$0.25 $0.16**  **$1.07 $0.00**  **$0.06 $0.04**  **$0.00 $0.11**  Extrude, autoclave on mandrel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 16 1 1 16 **1.0 1.0** 

**$0.33 $0.26**  **$0.59 $0.00**  **$0.04 $0.02**  **$0.00 $0.06**  Slip on sheath to coolant line and add clamps. Attach strap on hose clip and zip tie - trim to length. Add clamp on xmas tree to asm. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 62 4 1 62 **1.0 3.0** 

**$0.14 $0.11**  **$0.25 $0.00**  **$0.01 $0.01**  **$0.00 $0.03**  Attach clips to hose **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 26 2 1 26 **1.0 1.0** 

**$0.13 $0.10**  **$0.23 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  Place isolation ring onto trans coolant pump. Position clamp and bracket and snap onto trans coolant
pump **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 24.4 3 1 24.4 **1.0 1.0** 

**$0.20 $0.16**  **$0.36 $0.00**  **$0.02 $0.01**  **$0.00 $0.04**  Clamp coolant lines to trans coolant pump **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 38 2 1 38 **1.0 2.0** 

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

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

- - - - **1.0 1.0** 


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

1A H Aux Heater Cir Pump 021301-N0502-02



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

H Foam Pad, Self Stick, Pump Bracket 021301-N0502-29 H Hose Clamp, Medium (27mm) 021301-N0502-30 H Sheath, (15/16"), Pump to Dc-Dc Module 021301-N0502-31 H Hose Clamp, Medium (27mm) 021301-N0502-32 H Strap On Hose Clip (#7) 021301-N0502-33 H Clamp On Christmas Tree Clip 021301-N0502-34 H Zip Tie 021301-N0502-35 **5 2**  **10 100**  **47 4700** 

**$1.63 $3.22**  **$25.70 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

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

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

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

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

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

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

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

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

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

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

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

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

- - - - **1.0 1.0** 

**$0.00 $0.01**  **$0.46 $1.19**  **$0.23 $0.04**  **$0.08 $0.01**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 7 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up**  **Total**
**$3.09 $4.49**  **$31.93 $0.01**  **$0.25 $0.17**  **$0.00 $0.44** 

**$32.37 2** 



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



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 8 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 9 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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

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

-

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

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

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

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

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

-



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

H Isolation Ring, Mount, Coolant Pump 021301-N0502-19 **#DIV/0! #DIV/0!** 

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

-

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

- **1091 3.30**  1.00 H Clamp, Mount, Coolant Pump 021301-N0502-20

H Bracket, Mount, Coolant Pump 021301-N0502-21

021301-N0502-21A

021301-N0502-21B

021301-N0502-21C H Clamp On Christmas Tree Clip 021301-N0502-22

H Coolant Line, Pump to E Motor 021301-N0502-23 **3000 1.20**  1.00

**277 13.00**  0.50

**152 23.67**  0.50

**277 13.00**  0.25

**5143 0.70**  0.50
**3273 1.10**  1.00

**522 6.90**  1.00



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 10 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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

H Coolant Line, DC-DC to Pump 021301-N0502-24

H Coolant Line Asm, DC-DC to Pump 021301-N0502-25

H Coolant Line Asm, Pump to E motor 021301-N0502-26

H Trans Coolant Pump w/Mount 021301-N0502-27

H Trans Coolant Pump Sub Asm. 021301-N0502-28**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**225 16.00**  1.00

**174 20.67**  1.50

**138 26.00**  0.50

**148 24.40**  0.50

**189 19.00**  1.00

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

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

- 

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

1A H Aux Heater Cir Pump 021301-N0502-02



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

H Foam Pad, Self Stick, Pump Bracket 021301-N0502-29 H Hose Clamp, Medium (27mm) 021301-N0502-30 H Sheath, (15/16"), Pump to Dc-Dc Module 021301-N0502-31 H Hose Clamp, Medium (27mm) 021301-N0502-32 H Strap On Hose Clip (#7) 021301-N0502-33 H Clamp On Christmas Tree Clip 021301-N0502-34 H Zip Tie 021301-N0502-35 **#DIV/0! #DIV/0!** 

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

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

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

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

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

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

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

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

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

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

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

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

-



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 11 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 12 of 12 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 15 

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

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT** 

## Annual Component Volume: Shipping Method: **Component Description: H - Cooler Asm Trans DC DC Mod C**  

## Part Number: **021104-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

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

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

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

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

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

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
5 **0 #####**  **0 1**  **1.1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### Costs Broken Out Into Categories with Quantity per Assembly Taken into Account **TOTAL COSTS TOOLING & INVESTMENT**  

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

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

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

2 H Hose, Trans Cooler 021304-N0502-37 **1** Cut/Extrude T2/T3 Comp./Ext. Mold, SSLC Thermoset-SBR Extruding/Drawing Operator Extrusion Molding, NR, SS **720 1**  **1 1**  0.2270 **$1.32 $56.05**  **$35.94 $35.94**  **$0.30 $0.08**  **$0.05 $0.43**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.47 $0.47**  **$0.30**

H Hose, Trans Cooler 021304-N0502-37 Cut/Extrude T2/T3 Comp./Ext. Mold, SSLC Thermoset-SBR Extruding/Drawing Operator Extrusion Molding, NR, SS

3 H Rubber Tube, 17 mm Diam 021304-N0502-38 **1** Cut/Extrude T2/T3 Comp./Ext. Mold, SSLC Thermoset-EPDM Extruding/Drawing Operator Extrusion Molding, NR, SS **6000 1**  **1 1**  0.0080 **$1.83 $56.05**  **$35.94 $35.94**  **$0.01 $0.01**  **$0.01 $0.03**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.00**  **$0.03 $0.03**  **$0.01**

4 H Pipe, Tube Asm, Trans Cooler Asm. 021304-N0502-39 **1** Bend/Flare ends T2/T3 Comp./Ext. Mold, SSLC Aluminum-3000S, Coil Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC **113 0.5**  **1 1**  0.1026 **$0.84 $42.73**  **$50.00 $50.00**  **$0.09 $0.19**  **$0.44 $0.72**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.07**  **$0.79 $0.79**  **$0.09**

5 H Fitting, Tube Asm, 021304-N0502-40 **1** Debur T2/T3 CNC Milling, SSLC Not Applicable Grinding/Polishing Operator Grinding, SS **327 1**  **1 1**  0.000 **$0.00 $42.14**  **$45.00 $45.00**  **$0.00 $0.13**  **$0.14 $0.27**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.29 $0.29**  **$0.00**
6 021304-N0502-40A **1** Machine T2/T3 CNC Turning, SSLC Not Applicable CNC Operator CNC Machining, LC **159 1.5**  **3 1**  0.000 **$0.00 $36.98**  **$30.38 $91.14**  **$0.00 $0.35**  **$0.57 $0.92**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.10**  **$1.02 $1.02**  **$0.00**

7 021304-N0502-40B **1** Cut/Extrude T2/T3 Comp./Ext. Mold, SSLC Aluminum-4032, Bar Extruding/Drawing Operator Extrusion Molding, NR, SS **554 1**  **1 1**  0.0739 **$1.44 $56.05**  **$35.94 $35.94**  **$0.11 $0.10**  **$0.06 $0.27**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.30 $0.30**  **$0.11**

8 H Fluid Pipe Fitting Exchanger Asm. 021304-N0502-41 **1** Debur T2/T3 CNC Milling, SSLC Not Applicable Grinding/Polishing Operator Grinding, SS **327 1**  **1 1**  0.000 **$0.00 $42.14**  **$45.00 $45.00**  **$0.00 $0.13**  **$0.14 $0.27**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.29 $0.29**  **$0.00**
9 021304-N0502-41A **1** Machine T2/T3 CNC Turning, SSLC Not Applicable CNC Operator CNC Machining, LC **309 1.5**  **3 1**  0.000 **$0.00 $36.98**  **$30.38 $91.14**  **$0.00 $0.18**  **$0.30 $0.48**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.05**  **$0.52 $0.52**  **$0.00**



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 15 

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

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT** 

## Annual Component Volume: Shipping Method: **Component Description: H - Cooler Asm Trans DC DC Mod C**  

## Part Number: **021104-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

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

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

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

10 021304-N0502-41B **1** Cut/Extrude T2/T3 Comp./Ext. Mold, SSLC Aluminum-4032, Bar Extruding/Drawing Operator Extrusion Molding, NR, SS **900 1**  **1 1**  0.0594 **$1.44 $56.05**  **$35.94 $35.94**  **$0.09 $0.06**  **$0.04 $0.19**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.21 $0.21**  **$0.09**

11 H Locator Bracket, Exchanger 021304-N0502-42 **1** Debur T2/T3 CNC Milling, SSLC Not Applicable Grinding/Polishing Operator Grinding, SS **327 1**  **1 1**  0.000 **$0.00 $42.14**  **$45.00 $45.00**  **$0.00 $0.13**  **$0.14 $0.27**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.29 $0.29**  **$0.00**

12 021304-N0502-42A **1** T2/T3 Stamp/Form, SSLC T2/T3 Comp./Ext. Mold, SSLC Aluminum-3000S, Coil Cut/Punch/Forming Operator CNC Form, SS, LC **900 1**  **1 1**  0.0299 **$0.84 $42.73**  **$25.00 $25.00**  **$0.03 $0.05**  **$0.03 $0.10**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.11 $0.11**  **$0.03**

13 H RH Mounting Bracket, Exchanger 021304-N0502-43 **1** Debur T2/T3 CNC Milling, SSLC Not Applicable Grinding/Polishing Operator Grinding, SS **327 1**  **1 1**  0.000 **$0.00 $42.14**  **$45.00 $45.00**  **$0.00 $0.13**  **$0.14 $0.27**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.29 $0.29**  **$0.00**
14 021304-N0502-43A **1** Machine T2/T3 CNC Turning, SSLC Not Applicable CNC Operator CNC Machining, LC **831 1.5**  **3 1**  0.000 **$0.00 $36.98**  **$30.38 $91.14**  **$0.00 $0.07**  **$0.11 $0.18**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.19 $0.19**  **$0.00**

15 021304-N0502-43B **1** T2/T3 Stamp/Form, SSLC T2/T3 Comp./Ext. Mold, SSLC Aluminum-3000S, Coil Cut/Punch/Forming Operator CNC Form, SS, LC **900 1**  **1 1**  0.0293 **$0.84 $42.73**  **$25.00 $25.00**  **$0.02 $0.05**  **$0.03 $0.10**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.11 $0.11**  **$0.02**

16 H Locator Bracket, Exchanger 021304-N0502-44 **1** Debur T2/T3 CNC Milling, SSLC Not Applicable Grinding/Polishing Operator Grinding, SS **327 1**  **1 1**  0.000 **$0.00 $42.14**  **$45.00 $45.00**  **$0.00 $0.13**  **$0.14 $0.27**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.29 $0.29**  **$0.00**

17 021304-N0502-44A **1** T2/T3 Stamp/Form, SSLC T2/T3 Comp./Ext. Mold, SSLC Aluminum-3000S, Coil Cut/Punch/Forming Operator CNC Form, SS, LC **900 1**  **1 1**  0.0299 **$0.84 $42.73**  **$25.00 $25.00**  **$0.03 $0.05**  **$0.03 $0.10**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.11 $0.11**  **$0.03**

18 H LH Mounting Bracket, Exchanger 021304-N0502-45 **1** Debur T2/T3 CNC Milling, SSLC Not Applicable Grinding/Polishing Operator Grinding, SS **327 1**  **1 1**  0.000 **$0.00 $42.14**  **$45.00 $45.00**  **$0.00 $0.13**  **$0.14 $0.27**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.29 $0.29**  **$0.00**
19 021304-N0502-45A **1** Machine T2/T3 CNC Turning, SSLC Not Applicable CNC Operator CNC Machining, LC **831 1.5**  **3 1**  0.000 **$0.00 $36.98**  **$30.38 $91.14**  **$0.00 $0.07**  **$0.11 $0.18**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.19 $0.19**  **$0.00**

20 021304-N0502-45B **1** T2/T3 Stamp/Form, SSLC T2/T3 Comp./Ext. Mold, SSLC Aluminum-3000S, Coil Cut/Punch/Forming Operator CNC Form, SS, LC **900 1**  **1 1**  0.0288 **$0.84 $42.73**  **$25.00 $25.00**  **$0.02 $0.05**  **$0.03 $0.10**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.11 $0.11**  **$0.02**

21 H Return Tube, Exchanger Asm. 021304-N0502-46 **1** Bend/Flare ends T2/T3 Comp./Ext. Mold, SSLC Aluminum-3000S, Coil Cut/Punch/Forming Operator Hydro/CNC Form, SMS, LMC **100 0.5**  **1 1**  0.0361 **$0.84 $42.73**  **$50.00 $50.00**  **$0.03 $0.21**  **$0.50 $0.74**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.08**  **$0.82 $0.82**  **$0.03**

22 H Tank Endcap, Exchanger 021304-N0502-47 **2** Stamp T2/T3 Stamp/Form, MSMC Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **5143 0.5**  **1 1**  0.011 **$0.84 $42.73**  **$15.50 $15.50**  **$0.01 $0.00**  **$0.00 $0.02**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.00**  **$0.02 $0.04**  **$0.02**
23 H Tank Endcap, Exchanger 021304-N0502-48 **2** Stamp T2/T3 Stamp/Form, MSMC Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **5143 0.5**  **1 1**  0.011 **$0.84 $42.73**  **$15.50 $15.50**  **$0.01 $0.00**  **$0.00 $0.02**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.00**  **$0.02 $0.04**  **$0.02**
24 H LH Outboard Tank, Exchanger 021304-N0502-49 **1** Stamp T2/T3 Stamp/Form, MSMC Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **5143 0.5**  **1 1**  0.069 **$0.84 $42.73**  **$15.50 $15.50**  **$0.06 $0.00**  **$0.00 $0.07**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.01**  **$0.07 $0.07**  **$0.06**
25 H RH Outboard Tank, Exchanger 021304-N0502-50 **1** Stamp T2/T3 Stamp/Form, MSMC Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **5143 0.5**  **1 1**  0.069 **$0.84 $42.73**  **$15.50 $15.50**  **$0.06 $0.00**  **$0.00 $0.07**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.01**  **$0.07 $0.07**  **$0.06**
26 H Inboard Tank, Exchanger 021304-N0502-51 **1** Stamp T2/T3 Stamp/Form, MSMC Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS **2000 0.5**  **1 1**  0.069 **$0.84 $42.73**  **$42.91 $42.91**  **$0.06 $0.01**  **$0.02 $0.09**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.01**  **$0.10 $0.10**  **$0.06**
27 H Inboard Tank, Exchanger 021304-N0502-52 **1** Stamp T2/T3 Stamp/Form, MSMC Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS **2000 0.5**  **1 1**  0.069 **$0.84 $42.73**  **$42.91 $42.91**  **$0.06 $0.01**  **$0.02 $0.09**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.01**  **$0.10 $0.10**  **$0.06**
28 H Tube Exchanger Asm 021304-N0502-53 **17** Debur T2/T3 CNC Milling, SSLC Not Applicable Grinding/Polishing Operator Grinding, SS **327 1**  **1 1**  0.000 **$0.00 $42.14**  **$45.00 $45.00**  **$0.00 $0.13**  **$0.14 $0.27**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.29 $4.99**  **$0.00**

29 021304-N0502-54 **17** T2/T3 Stamp/Form, SSLC T2/T3 Comp./Ext. Mold, SSLC Aluminum-3003, Coil A Cut/Punch/Forming Operator CNC Form, SS, LC **3600 0.5**  **1 1**  0.1075 **$1.41 $42.73**  **$25.00 $25.00**  **$0.15 $0.01**  **$0.01 $0.16**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.18 $3.08**  **$2.58**

30 H Fin Exchanger Asm 021304-N0502-55 **16** Roll Form T2/T3 Stamp/Form, MSMC Aluminum-3000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS **4500 0.5**  **1 1**  0.0346 **$0.84 $42.73**  **$42.91 $42.91**  **$0.03 $0.00**  **$0.01 $0.04**  **0.50% 6.50%**  **6.00% 1.00%**  **14.00% $0.01**  **$0.05 $0.79**  **$0.47**

31 H Hose Asm, Trans Cooler 021304-N0502-56 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **144 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.13**  **$0.10 $0.24**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.26 $0.26**  **$0.00**

32 H Tube Asm, Trans Cooler Asm. 021304-N0502-57 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **189 1**  **2 1**  0.000 **$0.00 $38.55**  **$15.00 $30.00**  **$0.00 $0.20**  **$0.16 $0.36**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.40 $0.40**  **$0.00**

33 H Tube & Hose Asm, Trans Cooler Asm. 021304-N0502-58 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **121 1.5**  **3 1**  0.000 **$0.00 $38.55**  **$15.00 $45.00**  **$0.00 $0.48**  **$0.37 $0.85**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.09**  **$0.93 $0.93**  **$0.00**

34 H RH Outboard Tank, Exchanger 021304-N0502-59 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **158 1.5**  **2 1**  0.000 **$0.00 $38.55**  **$15.00 $30.00**  **$0.00 $0.37**  **$0.19 $0.56**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.06**  **$0.61 $0.61**  **$0.00**

35 H LH Outboard Tank, Exchanger 021304-N0502-60 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **134 1.5**  **2 1**  0.000 **$0.00 $38.55**  **$15.00 $30.00**  **$0.00 $0.43**  **$0.22 $0.65**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.07**  **$0.72 $0.72**  **$0.00**

36 H Cooler Core Asm, Exchanger 021304-N0502-61 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **118 2.5**  **5 1**  0.000 **$0.00 $38.55**  **$15.00 $75.00**  **$0.00 $0.82**  **$0.64 $1.46**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.15**  **$1.61 $1.61**  **$0.00**

37 H Cooler Asm, Trans & DC-DC Mod 021304-N0502-62 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **144 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.13**  **$0.10 $0.24**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.02**  **$0.26 $0.26**  **$0.00**

H Cooler Asm, Trans & DC-DC Mod 021304-N0502-62 Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base

38 H Exchanger Asm, Trans Cooler Asm. 021304-N0502-62A **1** Paint T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **257 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.04**  **$0.06 $0.10**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.11 $0.11**  **$0.00**

39 021304-N0502-62B **1** Oven Braze T2/T3 Heat Treat, SSLC Not Applicable Heat Treat Operator T5-Al380, SMS **124 1.5**  **1 1**  0.000 **$0.00 $47.72**  **$10.17 $10.17**  **$0.00 $0.58**  **$0.08 $0.66**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.07**  **$0.73 $0.73**  **$0.00**

40 021304-N0502-62C **1** Wash T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Washing Equipment, LC **257 0.25**  **1 1**  0.000 **$0.00 $38.55**  **$10.75 $10.75**  **$0.00 $0.04**  **$0.04 $0.08**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.09 $0.09**  **$0.00**

41 021304-N0502-62 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **212 1**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.18**  **$0.07 $0.25**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.03**  **$0.28 $0.28**  **$0.00**

42 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
43 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
44 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
45 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 15 

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

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT** 

## Annual Component Volume: Shipping Method: **Component Description: H - Cooler Asm Trans DC DC Mod C**  

## Part Number: **021104-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

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

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

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

46 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### C 

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

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
18 **##### 0**  **1 1**  0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### D 

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

**Price/ Unit**  **Purchase**

**Price Net, PIA**  **Purchase**

**Price Net, End Item** 

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

2 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

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

Assembly.
3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

5 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

4 H Oetiker Clamp, Medium (26.5mm) 021304-N0502-63 **1** S **$0.00** $0.25 **$0.00 $0.25**  **$0.25**

7 H Hose Clamp, Medium (27mm) 021304-N0502-64 **1** S **$0.00** $0.23 **$0.00 $0.23**  **$0.23**
8 H O-Ring, 18.5 x 2.5 mm 021304-N0502-65 **1** S **$0.00** $0.06 **$0.00 $0.06**  **$0.06**
9 H Heat Shrink Fabric Tube, 21 mmm Diam 021304-N0502-66 **1** S **$0.00** $0.07 **$0.00 $0.07**  **$0.07**
10 H Bolt, Line Asm to Exchanger 021304-N0502-67 **1** S **$0.00** $0.06 **$0.00 $0.06**  **$0.06**

11 H Label, Cooler Asm. 021304-N0502-68 **1** S **$0.00** $0.10 **$0.00 $0.10**  **$0.10**

12 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

### "SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub

- Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark

- up Calculations.

"Alpha

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



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 4 of 15 

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

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT** 

## Annual Component Volume: Shipping Method: **Component Description: H - Cooler Asm Trans DC DC Mod C**  

## Part Number: **021104-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

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

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

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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

15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

22 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
23 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
**0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
25 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
26 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

27 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
28 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
29 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
30 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$4.80**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$22.83**

**T1 or OEM Total Manufacturing Cost: $4.80**  **$8.09 $7.84**  **$20.73 $0.06**  **$1.20 $0.82**  **$0.01 $2.10**  **$22.83**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% **(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.11 $1.48**  **$1.37 $0.57**  **$3.54**
**Base Cost Impact to Vehicle: $4.80**  **$8.09 $7.84**  **$20.73 $0.18**  **$2.69 $2.19**  **$0.58 $5.63**  **$26.36 $0**  **$0 Packaging Cost:**  **$0.10 Net Cost Impact to Vehicle:**  **$26.46**

**Packaging Cost per**  **Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

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



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

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: **3 1** 



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



### Reference Packaging Database for Additional Information Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.) Assume Plastic Returnable Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad **Packaging Cost per**  **Piece Tier Pad**  **Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging Price Per**  **Other #1**

**Pads Pallet/Rack**  **Other #2**

**Packaging Price Per**  **Other #2**

**Pads Pallet/Rack**  **Other #3**

**Packaging, Price Per**  **Other #3**

**Pads Pallet/Rack** 



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

### Packaging Cost Total: **$0.000** 

### Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base
Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 5 of 15 

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

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: C0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Moderate Assembly Complexity** 

## System Description: **2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT** 

## Annual Component Volume: Shipping Method: **Component Description: H - Cooler Asm Trans DC DC Mod C**  

## Part Number: **021104-N0502-01** 

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

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

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

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

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

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

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

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES Power-Split HEV Technology** 

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

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

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



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 15 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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



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

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

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

- - - - **1.0 1.0** 

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

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

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

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

- - - - **1.1 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**



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

H Hose, Trans Cooler 021304-N0502-37 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.08 $0.05**  **$0.43 $0.00**  **$0.03 $0.02**  **$0.00 $0.04**  Extrude, autoclave on mandrel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 5 1 1 5 **1.0 1.0**  H Hose, Trans Cooler 021304-N0502-37

H Rubber Tube, 17 mm Diam 021304-N0502-38

H Pipe, Tube Asm, Trans Cooler Asm. 021304-N0502-39

H Fitting, Tube Asm, 021304-N0502-40
021304-N0502-40A

021304-N0502-40B

H Fluid Pipe Fitting Exchanger Asm. 021304-N0502-41
021304-N0502-41A **$0.08 $0.05**  **$0.43 $0.00**  **$0.03 $0.02**  **$0.00 $0.04**  Extrude, autoclave on mandrel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 5 1 1 5 **1.0 1.0** 

**$0.01 $0.01**  **$0.03 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Extrude, autoclave on mandrel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.6 1 1 0.6 **1.0 1.0** 

**$0.19 $0.44**  **$0.72 $0.00**  **$0.04 $0.03**  **$0.00 $0.07**  Tube form and flare, Low complexity **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 32 1 1 32 **1.0 1.0** 

**$0.13 $0.14**  **$0.27 $0.00**  **$0.02 $0.01**  **$0.00 $0.03**  Debur **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 11 1 1 11 **1.0 1.0**  **$0.35 $0.57**  **$0.92 $0.00**  **$0.06 $0.04**  **$0.00 $0.10**  EC-300-ML Horizontal CNC **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 68 10 1 68 **1.0 3.0** 

**$0.10 $0.06**  **$0.27 $0.00**  **$0.02 $0.01**  **$0.00 $0.03**  Extruded Aluminum **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 6.5 1 1 6.5 **1.0 1.0** 

**$0.13 $0.14**  **$0.27 $0.00**  **$0.02 $0.01**  **$0.00 $0.03**  Debur **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 11 1 1 11 **1.0 1.0**  **$0.18 $0.30**  **$0.48 $0.00**  **$0.03 $0.02**  **$0.00 $0.05**  EC-300-ML Horizontal CNC **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 35 5 1 35 **1.0 3.0** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 7 of 15 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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

021304-N0502-41B

H Locator Bracket, Exchanger 021304-N0502-42

021304-N0502-42A

H RH Mounting Bracket, Exchanger 021304-N0502-43
021304-N0502-43A

021304-N0502-43B

H Locator Bracket, Exchanger 021304-N0502-44

021304-N0502-44A 

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

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$0.06 $0.04**  **$0.19 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  Extruded Aluminum **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 4 1 1 4 **1.0 1.0** 

**$0.13 $0.14**  **$0.27 $0.00**  **$0.02 $0.01**  **$0.00 $0.03**  Debur **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 11 1 1 11 **1.0 1.0** 

**$0.05 $0.03**  **$0.10 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  Cut to size - cut off tool **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 4 1 1 4 **1.0 1.0** 

**$0.13 $0.14**  **$0.27 $0.00**  **$0.02 $0.01**  **$0.00 $0.03**  Debur **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 11 1 1 11 **1.0 1.0**  **$0.07 $0.11**  **$0.18 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  EC-300-ML Horizontal CNC **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 3.0** 

**$0.05 $0.03**  **$0.10 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  Cut to size **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 4 1 1 4 **1.0 1.0** 

**$0.13 $0.14**  **$0.27 $0.00**  **$0.02 $0.01**  **$0.00 $0.03**  Debur **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 11 1 1 11 **1.0 1.0** 

**$0.05 $0.03**  **$0.10 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  Extruded Aluminum **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 4 1 1 4 **1.0 1.0** 

H LH Mounting Bracket, Exchanger 021304-N0502-45
021304-N0502-45A

021304-N0502-45B

H Return Tube, Exchanger Asm. 021304-N0502-46

H Tank Endcap, Exchanger 021304-N0502-47 H Tank Endcap, Exchanger 021304-N0502-48 H LH Outboard Tank, Exchanger 021304-N0502-49 H RH Outboard Tank, Exchanger 021304-N0502-50 H Inboard Tank, Exchanger 021304-N0502-51 H Inboard Tank, Exchanger 021304-N0502-52 H Tube Exchanger Asm 021304-N0502-53

021304-N0502-54

H Fin Exchanger Asm 021304-N0502-55

H Hose Asm, Trans Cooler 021304-N0502-56

H Tube Asm, Trans Cooler Asm. 021304-N0502-57

H Tube & Hose Asm, Trans Cooler Asm. 021304-N0502-58

H RH Outboard Tank, Exchanger 021304-N0502-59

H LH Outboard Tank, Exchanger 021304-N0502-60

H Cooler Core Asm, Exchanger 021304-N0502-61

H Cooler Asm, Trans & DC-DC Mod 021304-N0502-62 **$0.13 $0.14**  **$0.27 $0.00**  **$0.02 $0.01**  **$0.00 $0.03**  Cut to size **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 11 1 1 11 **1.0 1.0**  **$0.07 $0.11**  **$0.18 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  EC-300-ML Horizontal CNC **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 13 1 1 13 **1.0 3.0** 

**$0.05 $0.03**  **$0.10 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  Cut to size **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 4 1 1 4 **1.0 1.0** 

**$0.21 $0.50**  **$0.74 $0.00**  **$0.04 $0.03**  **$0.00 $0.08**  Extruded Aluminum **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 36 1 1 36 **1.0 1.0** 

**$0.01 $0.01**  **$0.03 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  0-60 ton progressive die **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  **15.98** 0.7 1 1 0.7 **1.0 1.0**  **$0.01 $0.01**  **$0.03 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  0-60 ton progressive die **5 2**  **10 100**  **47 4700**  **191 18.80**  **85% 225**  **15.98** 0.7 1 1 0.7 **1.0 1.0**  **$0.00 $0.00**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  0-60 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.7 1 1 0.7 **1.0 1.0**  **$0.00 $0.00**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  0-60 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 0.7 1 1 0.7 **1.0 1.0**  **$0.01 $0.02**  **$0.09 $0.00**  **$0.01 $0.01**  **$0.00 $0.01**  200-400 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1.8 1 1 1.8 **1.0 1.0**  **$0.01 $0.02**  **$0.09 $0.00**  **$0.01 $0.01**  **$0.00 $0.01**  200-400 ton progressive die **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 1.8 1 1 1.8 **1.0 1.0**  **$2.19 $2.34**  **$4.53 $0.01**  **$0.27 $0.18**  **$0.00 $0.47**  Debur **5 2**  **10 100**  **47 4700**  **1628 2.21**  **85% 1915**  **1.88** 11 1 1 11 **1.0 1.0** 

**$0.10 $0.12**  **$2.80 $0.01**  **$0.17 $0.11**  **$0.00 $0.29**  Cut to size **5 2**  **10 100**  **47 4700**  **1628 2.21**  **85% 1915**  **1.88** 3.0 1 1 1.0 **1.0 1.0** 

**$0.08 $0.15**  **$0.69 $0.00**  **$0.05 $0.04**  **$0.01 $0.10**  Roll Form **5 2**  **10 100**  **47 4700**  **1532 2.35**  **85% 1802**  **2.00** 0.8 1 1 0.8 **1.0 1.0** 

**$0.13 $0.10**  **$0.24 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  Retract hose clamps and slip on hose. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 25 2 1 25 **1.0 1.0** 

**$0.20 $0.16**  **$0.36 $0.00**  **$0.02 $0.01**  **$0.00 $0.04**  Press firtting onto pipe **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 38 2 1 38 **1.0 2.0** 

**$0.48 $0.37**  **$0.85 $0.00**  **$0.05 $0.03**  **$0.00 $0.09**  Press hose on tube. Crimp Slide on rubber tube and heat shink sleeve. Slip on O-ring. Crimp Oetiker clamp. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 89 5 1 89 **1.0 3.0** 

**$0.37 $0.19**  **$0.56 $0.00**  **$0.03 $0.02**  **$0.00 $0.06**  Peen end caps onto outboard tank **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 46 1 1 46 **1.0 2.0** 

**$0.43 $0.22**  **$0.65 $0.00**  **$0.04 $0.03**  **$0.00 $0.07**  Peen end caps onto outboard tank and attach return pipe **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 54 1 1 54 **1.0 2.0** 

**$0.82 $0.64**  **$1.46 $0.00**  **$0.09 $0.06**  **$0.00 $0.15**  Stack 17 tubes and 16 fins **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 153 1 1 153 **1.0 5.0** 

**$0.13 $0.10**  **$0.24 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  Bolt tube & hose asm trans cooler to exchange asm trans cooler. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 25 1 1 25 **1.0 1.0**  H Cooler Asm, Trans & DC-DC Mod 021304-N0502-62

H Exchanger Asm, Trans Cooler Asm. 021304-N0502-62A

021304-N0502-62B

021304-N0502-62C

021304-N0502-62 **$0.13 $0.10**  **$0.24 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  Bolt tube & hose asm trans cooler to exchange asm trans cooler. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 25 1 1 25 **1.0 1.0** 

**$0.04 $0.06**  **$0.10 $0.00**  **$0.01 $0.00**  **$0.00 $0.01**  Spray Paint **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 14 1 1 14 **1.0 1.0** 

**$0.58 $0.08**  **$0.66 $0.00**  **$0.04 $0.03**  **$0.00 $0.07**  Oven Braze **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 29 1 1 29 **1.0 1.0** 

**$0.04 $0.04**  **$0.08 $0.00**  **$0.00 $0.00**  **$0.00 $0.01** 
Batch Wash **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 14 1 1 14 **1.0 1.0** 

**$0.18 $0.07**  **$0.25 $0.00**  **$0.02 $0.01**  **$0.00 $0.03**  Add label **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 17 1 1 17 **1.0 1.0** 

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

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

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

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

- - - - **1.0 1.0** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 8 of 15 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

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

- - - - **1.0 1.0** 

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

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

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

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

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

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

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

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

- - - - **1.0 1.0** 



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00**

H Oetiker Clamp, Medium (26.5mm) 021304-N0502-63 H Hose Clamp, Medium (27mm) 021304-N0502-64 H O-Ring, 18.5 x 2.5 mm 021304-N0502-65 H Heat Shrink Fabric Tube, 21 mmm Diam 021304-N0502-66 H Bolt, Line Asm to Exchanger 021304-N0502-67 H Label, Cooler Asm. 021304-N0502-68 **$0.00 $0.00**  **$0.00 $0.25**  **$0.23 $0.06**  **$0.07 $0.06**  **$0.10 $0.00**  **$0.00 $0.00** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 9 of 15 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up**  **Total**
**$8.09 $7.84**  **$20.73 $0.06**  **$1.20 $0.82**  **$0.01 $2.10** 

**$22.83 2** 



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



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 10 of 15 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

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



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

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Process Information **Gross Mark-up Costs x Quantity Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**  **Projected Operating Pattern MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Minimum Calculated Cycles Time**

File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 11 of 15 

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

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



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

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

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

-

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

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

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

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

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

-



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

H Hose, Trans Cooler 021304-N0502-37 **#DIV/0! #DIV/0!** 

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

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

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

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**720 5.00**  1.00 H Hose, Trans Cooler 021304-N0502-37

H Rubber Tube, 17 mm Diam 021304-N0502-38

H Pipe, Tube Asm, Trans Cooler Asm. 021304-N0502-39

H Fitting, Tube Asm, 021304-N0502-40
021304-N0502-40A

021304-N0502-40B

H Fluid Pipe Fitting Exchanger Asm. 021304-N0502-41
021304-N0502-41A **720 5.00**  1.00

**6000 0.60**  1.00

**113 32.00**  0.50

**327 11.00**  1.00
**159 22.67**  1.50

**554 6.50**  1.00

**327 11.00**  1.00
**309 11.67**  1.50



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 12 of 15 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

021304-N0502-41B

H Locator Bracket, Exchanger 021304-N0502-42

021304-N0502-42A

H RH Mounting Bracket, Exchanger 021304-N0502-43
021304-N0502-43A

021304-N0502-43B

H Locator Bracket, Exchanger 021304-N0502-44

021304-N0502-44A**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**900 4.00**  1.00

**327 11.00**  1.00

**900 4.00**  1.00

**327 11.00**  1.00
**831 4.33**  1.50

**900 4.00**  1.00

**327 11.00**  1.00

**900 4.00**  1.00

H LH Mounting Bracket, Exchanger 021304-N0502-45
021304-N0502-45A

021304-N0502-45B

H Return Tube, Exchanger Asm. 021304-N0502-46

H Tank Endcap, Exchanger 021304-N0502-47 H Tank Endcap, Exchanger 021304-N0502-48 H LH Outboard Tank, Exchanger 021304-N0502-49 H RH Outboard Tank, Exchanger 021304-N0502-50 H Inboard Tank, Exchanger 021304-N0502-51 H Inboard Tank, Exchanger 021304-N0502-52 H Tube Exchanger Asm 021304-N0502-53

021304-N0502-54

H Fin Exchanger Asm 021304-N0502-55

H Hose Asm, Trans Cooler 021304-N0502-56

H Tube Asm, Trans Cooler Asm. 021304-N0502-57

H Tube & Hose Asm, Trans Cooler Asm. 021304-N0502-58

H RH Outboard Tank, Exchanger 021304-N0502-59

H LH Outboard Tank, Exchanger 021304-N0502-60

H Cooler Core Asm, Exchanger 021304-N0502-61

H Cooler Asm, Trans & DC-DC Mod 021304-N0502-62 **327 11.00**  1.00
**831 4.33**  1.50

**900 4.00**  1.00

**100 36.00**  0.50

**5143 0.70**  0.50
**5143 0.70**  0.50
**5143 0.70**  0.50
**5143 0.70**  0.50
**2000 1.80**  0.50
**2000 1.80**  0.50
**327 11.00**  1.00

**3600 1.00**  0.50

**4500 0.80**  0.50

**144 25.00**  0.50

**189 19.00**  1.00

**121 29.67**  1.50

**158 22.80**  1.50

**134 26.80**  1.50

**118 30.60**  2.50

**144 25.00**  0.50 H Cooler Asm, Trans & DC-DC Mod 021304-N0502-62

H Exchanger Asm, Trans Cooler Asm. 021304-N0502-62A

021304-N0502-62B

021304-N0502-62C

021304-N0502-62 **144 25.00**  0.50

**257 14.00**  0.25

**124 29.00**  1.50

**257 14.00**  0.25

**212 17.00**  1.00

**#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- 

### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 13 of 15 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

-



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

-

H Oetiker Clamp, Medium (26.5mm) 021304-N0502-63 H Hose Clamp, Medium (27mm) 021304-N0502-64 H O-Ring, 18.5 x 2.5 mm 021304-N0502-65 H Heat Shrink Fabric Tube, 21 mmm Diam 021304-N0502-66 H Bolt, Line Asm to Exchanger 021304-N0502-67 H Label, Cooler Asm. 021304-N0502-68



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 14 of 15 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 15 of 15 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Low Assembly Complexity** 

## System Description: **2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT** 

## Annual Component Volume: Shipping Method: **Component Description: H Trans Cooler Line Asm D**  

## Part Number: **021370-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
5 **0 #####**  **0 1**  **1.1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### 9,574

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000** 

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 H Trans Cooler Line, E Motor Cooling 021370-N0502-69 **1** Extrude T2/T3 Comp./Ext. Mold, SSLC Thermoset-SBR Extruding/Drawing Operator Extrusion Molding, NR, SS **293 1**  **1 1**  0.5426 **$1.32 $56.05**  **$35.94 $35.94**  **$0.72 $0.19**  **$0.12 $1.03**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.11**  **$1.14 $1.14**  **$0.72** 2 H Trans Cooler Line, E Motor Cooling 021370-N0502-69 **1** Extrude T2/T3 Comp./Ext. Mold, SSLC

3 H Trans Cooler Line Asm, E Motor Cooling 021370-N0502-70 **1** Assemble T2/T3 Mech. Assembly, SSLC Not Applicable General Assembly Mech Assembly, LC, Base **185 1**  **2 1**  0.000 **$0.00 $38.55**  **$15.00 $30.00**  **$0.00 $0.21**  **$0.16 $0.37**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.04**  **$0.41 $0.41**  **$0.00**

4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Low Assembly Complexity** 

## System Description: **2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT** 

## Annual Component Volume: Shipping Method: **Component Description: H Trans Cooler Line Asm D**  

## Part Number: **021370-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000** 

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**



### C 

## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier Account**  **Cost Purchase** 

**Price/ Unit**  **Purchase**

**Price Net, PIA**  **Purchase**

**Price Net, End Item** 

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

2 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

4 H Hose Clamp, Medium (24mm) 021370-N0502-71 **1** S **$0.00** $0.22 **$0.00 $0.22**  **$0.22**

5 H Hose Clamp, Medium (27mm) 021370-N0502-72 **1** S **$0.00** $0.23 **$0.00 $0.23**  **$0.23** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub

- Assembly. In addition component material cost is 5 H Hose Clamp, Medium (27mm) 021370-N0502-72 **1** S **$0.00** $0.23 **$0.00 $0.23**  **$0.23**

4 H Strap On Christmas Tree Clip (# 30) 021370-N0502-73 **1** S **$0.00** $0.04 **$0.00 $0.04**  **$0.04**

7 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
10 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

11 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

12 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### T1 or OEM for Final or Sub

- Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark

- up Calculations.

"Alpha

- Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Low Assembly Complexity** 

## System Description: **2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT** 

## Annual Component Volume: Shipping Method: **Component Description: H Trans Cooler Line Asm D**  

## Part Number: **021370-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000** 

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

21 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

22 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
23 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

24 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
25 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
26 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

27 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
28 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
29 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
30 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$1.21**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$2.04**

**T1 or OEM Total Manufacturing Cost: $1.21**  **$0.40 $0.29**  **$1.89 $0.00**  **$0.08 $0.06**  **$0.00 $0.14**  **$2.04**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- 0.30% 6.00% 4.00% 1.00% 11.30% **(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **$0.01 $0.12**  **$0.08 $0.02**  **$0.23**
**Base Cost Impact to Vehicle: $1.21**  **$0.40 $0.29**  **$1.89 $0.01**  **$0.21 $0.14**  **$0.02 $0.37**  **$2.27 $0**  **$0 Packaging Cost:**  **$0.02 Net Cost Impact to Vehicle:**  **$2.28**

**Packaging Cost per**  **Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Cost per**  **Piece Tier Pad**  **Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging Price Per**  **Other #1**

**Pads Pallet/Rack**  **Other #2**

**Packaging Price Per**  **Other #2**

**Pads Pallet/Rack**  **Other #3**

**Packaging, Price Per**  **Other #3**

**Pads Pallet/Rack**  

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: **3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### Reference Packaging Database for Additional Information Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.) Assume Plastic Returnable Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) **Piece Price Per**  **Pallet/Rack Price Per**  **Pallet/Rack Price Per**  **Pallet/Rack Price Per**  **Pallet/Rack Price Per**  **Pallet/Rack**



### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 

### Packaging Cost Total: **$0.000** 

### Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base
Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 4 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0502 (N = New, 05 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **T1 Low Assembly Complexity** 

## System Description: **2010 Ford Fusion, 3.0L V6, 4-Valve, DOHC, NA, PFI, iVVT** 

## Annual Component Volume: Shipping Method: **Component Description: H Trans Cooler Line Asm D**  

## Part Number: **021370-N0502-01** 

## We ekly Component Volume: Packaging Specification: **Returnable Dunnage** 

## Component Quote Level: Estimated Product Life: Production Year: **2009/2010**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000** 

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Power-Split HEV Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 5 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.1 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**



## Purchase Part - High Impact Item (Full Cost Mapping)

H Trans Cooler Line, E Motor Cooling 021370-N0502-69 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.19 $0.12**  **$1.03 $0.00**  **$0.06 $0.04**  **$0.00 $0.11**  Extrude, autoclave on mandrel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 12.3 1 1 12.3 **1.0 1.0**  H Trans Cooler Line, E Motor Cooling 021370-N0502-69

H Trans Cooler Line Asm, E Motor Cooling 021370-N0502-70 **$0.19 $0.12**  **$1.03 $0.00**  **$0.06 $0.04**  **$0.00 $0.11**  Extrude, autoclave on mandrel **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 12.3 1 1 12.3 **1.0 1.0** 

**$0.21 $0.16**  **$0.37 $0.00**  **$0.02 $0.01**  **$0.00 $0.04**  Retract hose clamps and slip on hose. Strap on xmas treee and attach zip tie **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96** 39 4 1 39 **1.0 2.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 



## Purchase Part - Commodity ( Value taken from Purchase Part Database)

H Hose Clamp, Medium (24mm) 021370-N0502-71 H Hose Clamp, Medium (27mm) 021370-N0502-72 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.22**  **$0.23** H Hose Clamp, Medium (27mm) 021370-N0502-72 H Strap On Christmas Tree Clip (# 30) 021370-N0502-73 **$0.04 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 7 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up**  **Total**
**$0.40 $0.29**  **$1.89 $0.00**  **$0.08 $0.06**  **$0.00 $0.14** 

**$2.04 2** 



### Notes: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 8 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 9 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

-



## Purchase Part - High Impact Item (Full Cost Mapping)

H Trans Cooler Line, E Motor Cooling 021370-N0502-69 **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

-

**293 12.30**  1.00 H Trans Cooler Line, E Motor Cooling 021370-N0502-69

H Trans Cooler Line Asm, E Motor Cooling 021370-N0502-70 **293 12.30**  1.00

**185 19.50**  1.00

**#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

-



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 10 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

-



## Purchase Part - Commodity ( Value taken from Purchase Part Database)

H Hose Clamp, Medium (24mm) 021370-N0502-71 H Hose Clamp, Medium (27mm) 021370-N0502-72 **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

-

H Hose Clamp, Medium (27mm) 021370-N0502-72 H Strap On Christmas Tree Clip (# 30) 021370-N0502-73



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 11 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 12 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

# 01 **14 H Trans & DC Cooling Sy**  **stem QTY**  **$$$**
**H Trans & DC Cooling System** 

# 2.48

x H Bolt Trans Coolant Bottle 

# 1 0.07

x H Nut Trans Coolant Bottle 

# 1 0.07

x H Bolt, Trans Coolant Pump 

# 2 0.14

x H Bolt, Trans Cooler to FEM 

# 1 0.07

x H Bolt, Trans Cooler to FEM 

# 1 0.07

x A **H Bottle A sm w/Hose, Trans Coolant**  

# 1 0.19

x A1 **H Bottle A sm,Trans Coolant**  

# 1 0.35

x H Label, Trans Cooler Bottle 

# 1 0.11

x A1A **H Bottle, Trans Coolant, Welded** 

# 1 0.48

x H Bottle Bottom, Trans Coolant, Molded 

# 1 0.88

x H Bottle Top, Trans Coolant, Molded 

# 1 0.46

x A1B H Tube, Trans Coolant Bottle 

# 1 0.10

x A1C **H Cap, Trans Coolant Bottle** 

# 1 0.29

x A2 **H Hose A sm, Coolant, Trans to Bottle**  

# 1 0.35

x H Hose, Coolant, Trans to Bottle 

# 1 0.36

x H Sheath, (15/16"), Bottle to Trans Hose 

# 1 0.21

x H Hose Clamp, Medium (24mm) 

# 1 0.26

x H Hose Clamp, Medium (22mm) 

# 1 0.24

x B **H Trans Coolant Pump Sub A sm.**  

# 1 0.44

x B1 **H Trans Coolant Pump w/Mount** 

# 1 0.36

x H Trans Coolant Pump 

# 1 29.68

x H Isolation Ring, Mount, Coolant Pump 

# 1 0.15

x H Clamp, Mount, Coolant Pump 

# 1 0.12

x B1A **H Bracket A sm, Mount, Cololant Pump**  

# 1 0.15

x H Bracket, Mount, Coolant Pump 

# 1 0.82

x H Foam Pad, Self Stick, Pump Bracket 

# 1 0.01

x B2 **H Coolant Line A sm, Pump to E motor**  

# 1 0.30

x H Coolant Line, Pump to E Motor 

# 1 0.79

x H Hose Clamp, Medium (27mm) 

# 2 0.54

x B3 **H Coolant Line A sm, DC-DC to Pump**  

# 1 0.72

x H Coolant Line, DC-DC to Pump 

# 1 1.36

x H Sheath, (15/16"), Pump to Dc-Dc Module 

# 1 1.37

x H Hose Clamp, Medium (27mm) 

# 2 0.54

x H Strap On Hose Clip (#7) 

# 1 0.05

x H Clamp On Christmas Tree Clip 

# 1 0.09

x H Zip Tie 

# 1 0.01

x C **H Cooler A sm, Trans & DC-DC Mod**  

# 1 0.24

x H Bolt, Line Asm to Exchanger 

# 1 0.07

x H Label, Cooler Asm. 

# 1 0.11

x C1 **H Exchanger A sm, Trans Cooler A** 

**sm.** 

# 1 1.34

x H Fluid Pipe Fitting Exchanger Asm. 

# 1 1.13

x H RH Mounting Bracket, Exchanger 

# 1 0.73

x H Locator Bracket, Exchanger 

# 1 0.50

x C1A **H Cooler Core A sm, Exchanger**  

# 1 1.77

x H Tube Exchanger Asm 

# 17 9.58

x H Fin Exchanger Asm 

# 16 0.91

# x C1B **H LH Outboard Tank, Exchanger** 

# 0.79

x H LH Outboard Tank, Exchanger 

# 1 0.09

x H Tank Endcap, Exchanger 

# 2 0.05

x H Inboard Tank, Exchanger 

# 1 0.12

x H Return Tube, Exchanger Asm. 

# 1 0.94

x H LH Mounting Bracket, Exchanger 

# 1 0.75

x H Locator Bracket, Exchanger 

# 1 0.53

x C1C **H RH Outboard Tank, Exchanger** 

# 1 0.67

x H Inboard Tank, Exchanger, 

# 1 0.12

x H Tank Endcap, Exchanger 

# 2 0.05

x H RH Outboard Tank, Exchanger 

# 1 0.09

x C2 **H Tube & Hose A sm, Trans Cooler A** 

**sm.** 

# 1 1.03

x H O-Ring, 18.5 x 2.5 mm 

# 1 0.07

x H Rubber Tube, 17 mm Diam 

# 1 0.04

x H Heat Shrink Fabric Tube, 21 mmm Diam 

# 1 0.08

x C2A **H Tube A sm, Trans Cooler A** 

**sm.** 

# 1 0.44

x H Pipe, Tube Asm, Trans Cooler Asm. 

# 1 0.92

x H Fitting, Tube Asm, 

# 1 1.80

x C2B **H Hose A sm, Trans Cooler**  

# 1 0.29

x H Hose, Trans Cooler 

# 1 0.55

x H Oetiker Clamp, Medium (26.5mm) 

# 1 0.29

x H Hose Clamp, Medium (27mm) 

# 1 0.27

x D **H Trans Cooler Line A sm, E Motor Cooling**  

# 1 0.45

x H Trans Cooler Line, E Motor Cooling 

# 1 1.31

x H Hose Clamp, Medium (24mm) 

# 1 0.25

x H Hose Clamp, Medium (27mm) 

# 1 0.27

x H Strap On Christmas Tree Clip (# 30) 

# 1 0.04

108 73.36

# Comments

Commodity Commodity Commodity Commodity Commodity

Commodity

Commodity Commodity Commodity

Commodity

Commodity

Commodity Commodity Commodity



# x Commodity Commodity



# x

x

# x

x

x Commodity

Commodity



# x

Commodity? 

# 26.36 Commodity

Commodity Commodity 

# 2.32 Commodity

# Indented Bill of Materials

**H Trans & DC-DC Cooling Sy stem** 
**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost Weight**  **Piece Cost Weight (Total)** 

**(Total) H Bottle A** 

**sm w/Hose, Trans H Bottle A**  **sm** 

# 0.8123 lb **0.8123 lb Coolant**  **w/Hose, Trans Coolant**  **1 H Bottle A** 

**sm, Trans Coolant H Bottle A**  **sm, 1**  **# 0.6344 lb**  **# 0.6344 lb**  **Trans Coolant 2**  **H Bottle, Trans Coolant H Bottle, Trans**  **1 #**  **0.6052 lb #**  **0.6052 lb Coolant**  **3 H Bottle, Trans Coolant,**  **H Bottle, Trans 1**  **Poly propy**  **lene #**  **0.5911 lb #**  **0.5911 lb Welded**  **Coolant, Welded**  **4 H Bottle Bottom, Trans**  **H Bottle 1**  **Poly propy**  **lene #**  **0.4138 lb #**  **0.4138 lb Coolant, Molded**  **Bottom, Trans Coolant,**  **Molded 5**  H Bottle Bottom, Trans H Bottle **1** Polypropylene **# 0.4138 lb**  **# 0.4138 lb**  Coolant, Material Bottom, Trans Coolant, Material **4 H Bottle Top, Trans Coolant,**  **H Bottle Top, 1**  **Poly propy**  **lene #**  **0.1773 lb #**  **0.1773 lb Molded**  **Trans Coolant, Molded**  **5** H Bottle Top, Trans Coolant, H Bottle Top, **1** Polypropylene **# 0.1773 lb**  **# 0.1773 lb**  Material Trans Coolant, Material **3 H Tube, Trans Coolant Bottle**  **H Tube, Trans 1**  **Stainless Steel #**  **0.0141 lb #**  **0.0141 lb Coolant Bottle**  **# 4**  H Tube, Trans Coolant Bottle, H Tube, Trans **1** Stainless Steel **# 0.0141 lb**  **# 0.0141 lb**  Material Coolant Bottle, # Material **2 H Cap, Trans Coolant Bottle**  **H Cap, Trans 1**  **Poly propy**  **lene #**  **0.0291 lb #**  **0.0291 lb Coolant Bottle**  **3 H Cap, Trans Coolant Bottle,**  **H Cap, Trans 1**  **Poly propy**  **lene #**  **0.0291 lb #**  **0.0291 lb Molded**  **Coolant Bottle, Molded**  **4** H Cap, Trans Coolant Bottle, H Cap, Trans **1** Polypropylene **# 0.0291 lb**  **# 0.0291 lb**  Material Coolant Bottle, Material


# Design Profit

®

# Page 1 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost Weight**  **Piece Cost Weight (Total)** 

**(Total)** H Label, Trans Cooler Bottle H Label, Trans 

# 1 Commodity 

# 0.0001 lb 0.0001 lb Cooler Bottle Pricing **1 H Hose A** 

**sm, Coolant, Trans H Hose A**  **sm, 1**  **# 0.1779 lb**  **# 0.1779 lb**  **to Bottle Coolant, Trans**  **to Bottle 2**  **H Hose, Coolant, Trans to H Hose,**  **1 SBR**  **# 0.1364 lb**  **# 0.1364 lb**  **Bottle, Extruded Coolant, Trans**  **to Bottle, Extruded**  **3** H Hose, Coolant, Trans to H Hose, **1** SBR **# 0.1364 lb**  **# 0.1364 lb**  Bottle, Material Coolant, Trans to Bottle, Material 2 H Sheath, (15/16"), Bottle to H Sheath, 1 Commodity # 0.0048 lb # 0.0048 lb Trans Hose (15/16"), Bottle Pricing to Trans Hose 2 H Hose Clamp, Medium H Hose Clamp, 1 Commodity # 0.0200 lb # 0.0200 lb (24mm) Medium Pricing (24mm) 2 H Hose Clamp, Medium H Hose Clamp, 1 Commodity # 0.0167 lb # 0.0167 lb (22mm) Medium Pricing (22mm) 0 H Bolt Trans Coolant Bottle H Bolt Trans 1 Commodity # 0.0208 lb # 0.0208 lb Coolant Bottle Pricing 0 H Nut Trans Coolant Bottle H Nut Trans 1 Commodity # 0.0106 lb # 0.0106 lb Coolant Bottle Pricing **0 H Trans Coolant Pump Sub**  **H Trans 1**  **# 1.6571 lb**  **# 1.6571 lb**  **As m**  **Coolant Pump Sub A**  **sm 1**  **H Trans Coolant Pump H Trans**  **1 #**  **0.6446 lb #**  **0.6446 lb w/Mount**  **Coolant Pump w/Mount**  **2 H Trans Coolant Pump**  **H Trans 1**  **Commodity #**  **0.3778 lb #**  **0.3778 lb Coolant Pump**  **Pricing 2**  **H Isolation Ring, Mount, H Isolation**  **1 SBR**  **# 0.0395 lb**  **# 0.0395 lb**  **Coolant Pump Ring, Mount,**  **Coolant Pump 3**  H Isolation Ring, Mount, H Isolation **1** SBR **# 0.0395 lb**  **# 0.0395 lb**  Coolant Pump, Material Ring, Mount, Coolant Pump, Material

# Design Profit ®

Page 2 of # Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost Weight**  **Piece Cost Weight (Total)** 

**(Total) H Clamp, Mount, Coolant**  **H Clamp,** 

# 1 **PA 66**  

# 0.0343 lb **0.0343 lb Pump**  **Mount, Coolant Pump**  **3** H Clamp, Mount, Coolant H Clamp, **1** PA66 **# 0.0343 lb**  **# 0.0343 lb**  Pump, Material Mount, Coolant Pump, Material **2 H Bracket A** 

**sm, Mount, H Bracket**  **1 #**  **0.1930 lb #**  **0.1930 lb Coolant Pump**  **As m, Mount,**  **Coolant Pump 3**  **H Bracket, Mount, Coolant H Bracket,**  **1 Steel - 1008**  **# 0.1929 lb**  **# 0.1929 lb**  **Pump Mount,**  **Coolant Pump 4**  **H Bracket, Mount, Coolant H Bracket,**  **1 Steel - 1008**  **# 0.1929 lb**  **# 0.1929 lb**  **Pump, Washed Mount,**  **Coolant Pump, Washed**  **5 H Bracket, Mount, Coolant**  **H Bracket, 1**  **Steel - 1008 #**  **0.1929 lb #**  **0.1929 lb Pump, Stamped**  **Mount, Coolant Pump,**  **Stamped 6**  H Bracket, Mount, Coolant H Bracket, **1** Steel - 1008 **# 0.1929 lb**  **# 0.1929 lb**  Pump, Material Mount, Coolant Pump, Material 3 H Foam Pad, Self Stick, Pump H Foam Pad, 1 Commodity # 0.0001 lb # 0.0001 lb Bracket Self Stick, Pricing Pump Bracket **1 H Coolant Line A** 

**sm, Pump H Coolant Line**  **1 #**  **0.3916 lb #**  **0.3916 lb to E Motor**  **As m, Pump to**  **E Motor 2**  **H Coolant Line, Pump to E H Coolant**  **1 EPDM**  **# 0.3404 lb**  **# 0.3404 lb**  **Motor Line, Pump to**  **E Motor 3**  H Coolant Line, Pump to E H Coolant Line, **1** EPDM **# 0.3404 lb**  **# 0.3404 lb**  Motor, Material Pump to E Motor, Material 2 H Hose Clamp, Medium H Hose Clamp, 2 Commodity # 0.0256 lb # 0.0512 lb (27mm) Medium Pricing (27mm) **1 H Coolant Line A** 

**sm, DC-DC H Coolant Line**  **1 #**  **0.6209 lb #**  **0.6209 lb to Pump**  **As m, DC-DC to**  **Pump**

# Design Profit ®

Page 3 of # Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost Weight**  **Piece Cost Weight (Total)** 

**(Total) H Coolant Line, DC-DC to**  **H Coolant** 

# 1 **0.5021 lb 0.5021 lb**  **Pump Line, DC-DC to**  **Pump 3**  H Coolant Line, DC-DC to H Coolant Line, **1** EPDM **# 0.5021 lb**  **# 0.5021 lb**  Pump, Material DC-DC to Pump, Material 2 H Sheath, (15/16"), Pump to H Sheath, 1 Commodity # 0.0381 lb # 0.0381 lb Dc-Dc Module (15/16"), Pump Pricing to Dc-Dc Module 2 H Hose Clamp, Medium H Hose Clamp, 2 Commodity # 0.0256 lb # 0.0512 lb (27mm) Medium Pricing (27mm) 2 H Strap On Hose Clip (#7) H Strap On 1 Commodity # 0.0096 lb # 0.0096 lb Hose Clip (#7) Pricing **2 H Clamp On Christmas Tree**  **H Clamp On 1**  **PA 66**  **# 0.0199 lb**  **# 0.0199 lb**  **Clip Christmas**  **Tree Clip 3**  H Clamp On Christmas Tree H Clamp On **1** PA66 **# 0.0199 lb**  **# 0.0199 lb**  Clip, Material Christmas Tree Clip, Material 0 H Bolt, Trans Coolant Pump H Bolt, Trans 2 Commodity # 0.0208 lb # 0.0416 lb H Bolt, Trans Coolant Pump H Bolt, Trans Commodity 0.0208 lb 0.0416 lb Coolant Pump Pricing **0 H Cooler A** 

**sm, Trans & H Cooler A**  **sm, 1**  **# 3.3818 lb**  **# 3.3818 lb**  **DC-DC Mod Trans &**  **DC-DC Mod 1**  **H Exchanger A**

**sm, Trans H Exchanger**  **1 Al**  **uminum- Mn #**  **2.8850 lb #**  **2.8850 lb Cooler A** 

**sm As**  **m, Trans - 30xx**  **Cooler A**

**sm 2**  **H Exchanger A**

**sm, Trans H Exchanger**  **1 Al**  **uminum- Mn #**  **2.8849 lb #**  **2.8849 lb Cooler, Painted**  **As m, Trans**  **- 30xx Cooler,**  **Painted 3**  **H Exchanger A**

**sm, Trans H Exchanger**  **1 Al**  **uminum- Mn #**  **2.8849 lb #**  **2.8849 lb Cooler, Washed**  **As m, Trans**  **- 30xx Cooler,**  **Washed 4**  **H Exchanger A**

**sm, Trans H Exchanger**  **1 Al**  **uminum- Mn #**  **2.8849 lb #**  **2.8849 lb Cooler, Brazed**  **As m, Trans**  **- 30xx Cooler, Brazed** 



# Design Profit

®

# Page 4 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**
**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost Weight**  **Piece Cost Weight (Total)** 

**(Total) H Exchanger A** 

**sm, H Exchanger**  **Al uminum- Mn**  

# # **2.8849 lb #**  **2.8849 lb As**  **sembled Loose As**  **m, - 30xx**  **As sembled**  **Loose 6**  **H Cooler Core A**

**sm, H Cooler Core**  **1 #**  **2.3803 lb #**  **2.3803 lb Exchanger**  **As m,**  **Exchanger 7**  **H Tube Exchanger A sm,**  **H Tube 1**  **Al uminum- Mn**  **# 0.1075 lb**  **# 0.1075 lb**  **Deburred Exchanger**  **- 30xx As**  **m, Deburred 8**  **H Tube Exchanger A sm,**  **H Tube 1**  **Al uminum- Mn**  **# 0.1075 lb**  **# 0.1075 lb**  **Extruded Exchanger**  **- 30xx As**  **m, Extruded 9**  H Tube Exchanger Asm, H Tube **1** Commodity **# 0.1075 lb**  **# 0.1075 lb**  Material Exchanger Pricing Asm, Material **7 H Fin, Exchanger A**  **sm, Roll H Fin,**  **1 Al**  **uminum- Mn #**  **0.0346 lb #**  **0.0346 lb Formed**  **Exchanger - 30xx**  **As m, Roll**  **Formed 8**  H Fin, Exchanger Asm, H Fin, **1** Aluminum- Mn - **# 0.0346 lb**  **# 0.0346 lb**  Material Exchanger 30xx - Clad Asm, Material **7 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Deburred**  **Exchanger - 30xx**  **As m, Deburred**  **8 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Extruded**  **Exchanger - 30xx**  **As m, Extruded**  **9** H Tube Exchanger Asm, H Tube **1** Commodity **# 0.1075 lb**  **# 0.1075 lb**  Material Exchanger Pricing Asm, Material **7 H Fin, Exchanger A**  **sm, Roll H Fin,**  **1 Al**  **uminum- Mn #**  **0.0346 lb #**  **0.0346 lb Formed**  **Exchanger - 30xx**  **As m, Roll**  **Formed 8**  H Fin, Exchanger Asm, H Fin, **1** Aluminum- Mn - **# 0.0346 lb**  **# 0.0346 lb**  Material Exchanger 30xx - Clad Asm, Material **7 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Deburred**  **Exchanger - 30xx**  **As m, Deburred** 


# Design Profit

®

# Page 5 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**
**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost Weight**  **Piece Cost Weight (Total)** 

**(Total) 8**  **H Tube Exchanger A sm,**  **H Tube Al**  **uminum- Mn** 

# 0.1075 lb **Extruded Exchanger**  **- 30xx As**  **m, Extruded 9**  H Tube Exchanger Asm, H Tube **1** Commodity **# 0.1075 lb**  **# 0.1075 lb**  Material Exchanger Pricing Asm, Material **7 H Fin, Exchanger A**  **sm, Roll H Fin,**  **1 Al**  **uminum- Mn #**  **0.0346 lb #**  **0.0346 lb Formed**  **Exchanger - 30xx**  **As m, Roll**  **Formed 8**  H Fin, Exchanger Asm, H Fin, **1** Aluminum- Mn - **# 0.0346 lb**  **# 0.0346 lb**  Material Exchanger 30xx - Clad Asm, Material **7 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Deburred**  **Exchanger - 30xx**  **As m, Deburred**  **8 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Extruded**  **Exchanger - 30xx**  **As m, Extruded**  **9** H Tube Exchanger Asm, H Tube **1** Commodity **# 0.1075 lb**  **# 0.1075 lb**  Material Exchanger Pricing Asm, Material **7 H Fin, Exchanger A**  **sm, Roll H Fin,**  **1 Al**  **uminum- Mn #**  **0.0346 lb #**  **0.0346 lb Formed**  **Exchanger - 30xx**  **As m, Roll**  **Formed 8**  H Fin, Exchanger Asm, H Fin, **1** Aluminum- Mn - **# 0.0346 lb**  **# 0.0346 lb**  Material Exchanger 30xx - Clad Asm, Material **7 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Deburred**  **Exchanger - 30xx**  **As m, Deburred**  **8 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Extruded**  **Exchanger - 30xx**  **As m, Extruded**  **9** H Tube Exchanger Asm, H Tube **1** Commodity **# 0.1075 lb**  **# 0.1075 lb**  Material Exchanger Pricing Asm, Material **7 H Fin, Exchanger A**  **sm, Roll H Fin,**  **1 Al**  **uminum- Mn #**  **0.0346 lb #**  **0.0346 lb Formed**  **Exchanger - 30xx**  **As m, Roll**  **Formed**


# Design Profit

®

# Page 6 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**
**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost Weight**  **Piece Cost Weight (Total)** 

**(Total)** 8 H Fin, Exchanger Asm, H Fin, Aluminum- Mn - 

# 0.0346 lb Material Exchanger 30xx - Clad Asm, Material **7 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Deburred**  **Exchanger - 30xx**  **As m, Deburred**  **8 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Extruded**  **Exchanger - 30xx**  **As m, Extruded**  **9** H Tube Exchanger Asm, H Tube **1** Commodity **# 0.1075 lb**  **# 0.1075 lb**  Material Exchanger Pricing Asm, Material **7 H Fin, Exchanger A**  **sm, Roll H Fin,**  **1 Al**  **uminum- Mn #**  **0.0346 lb #**  **0.0346 lb Formed**  **Exchanger - 30xx**  **As m, Roll**  **Formed 8**  H Fin, Exchanger Asm, H Fin, **1** Aluminum- Mn - **# 0.0346 lb**  **# 0.0346 lb**  Material Exchanger 30xx - Clad Asm, Material **7 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Deburred**  **Exchanger - 30xx**  **As m, Deburred**  **8 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Extruded**  **Exchanger - 30xx**  **As m, Extruded**  **9** H Tube Exchanger Asm, H Tube **1** Commodity **# 0.1075 lb**  **# 0.1075 lb**  Material Exchanger Pricing Asm, Material **7 H Fin, Exchanger A**  **sm, Roll H Fin,**  **1 Al**  **uminum- Mn #**  **0.0346 lb #**  **0.0346 lb Formed**  **Exchanger - 30xx**  **As m, Roll**  **Formed 8**  H Fin, Exchanger Asm, H Fin, **1** Aluminum- Mn - **# 0.0346 lb**  **# 0.0346 lb**  Material Exchanger 30xx - Clad Asm, Material **7 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Deburred**  **Exchanger - 30xx**  **As m, Deburred**  **8 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Extruded**  **Exchanger - 30xx**  **As m, Extruded** 

# Design Profit ®

Page 7 of # Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**
**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost Weight**  **Piece Cost Weight (Tota** 

**(Total)** 9 H Tube Exchanger Asm, H Tube Commodity 

# # 0.1075 lb Material Exchanger Pricing Asm, Material **7 H Fin, Exchanger A**  **sm, Roll H Fin,**  **1 Al**  **uminum- Mn #**  **0.0346 lb #**  **0.0346 lb Formed**  **Exchanger - 30xx**  **As m, Roll**  **Formed 8**  H Fin, Exchanger Asm, H Fin, **1** Aluminum- Mn - **# 0.0346 lb**  **# 0.0346 lb**  Material Exchanger 30xx - Clad Asm, Material **7 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Deburred**  **Exchanger - 30xx**  **As m, Deburred**  **8 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Extruded**  **Exchanger - 30xx**  **As m, Extruded**  **9** H Tube Exchanger Asm, H Tube **1** Commodity **# 0.1075 lb**  **# 0.1075 lb**  Material Exchanger Pricing Asm, Material **7 H Fin, Exchanger A**  **sm, Roll H Fin,**  **1 Al**  **uminum- Mn #**  **0.0346 lb #**  **0.0346 lb Formed**  **Exchanger - 30xx**  **As m, Roll**  **Formed 8**  H Fin, Exchanger Asm, H Fin, **1** Aluminum- Mn - **# 0.0346 lb**  **# 0.0346 lb**  Material Exchanger 30xx - Clad Asm, Material **7 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Deburred**  **Exchanger - 30xx**  **As m, Deburred**  **8 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Extruded**  **Exchanger - 30xx**  **As m, Extruded**  **9** H Tube Exchanger Asm, H Tube **1** Commodity **# 0.1075 lb**  **# 0.1075 lb**  Material Exchanger Pricing Asm, Material **7 H Fin, Exchanger A**  **sm, Roll H Fin,**  **1 Al**  **uminum- Mn #**  **0.0346 lb #**  **0.0346 lb Formed**  **Exchanger - 30xx**  **As m, Roll**  **Formed 8**  H Fin, Exchanger Asm, H Fin, **1** Aluminum- Mn - **# 0.0346 lb**  **# 0.0346 lb**  Material Exchanger 30xx - Clad Asm, Material


# Design Profit

®

# Page 8 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**
**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost Weight**  **Piece Cost Weight (Total)** 

**(Total) 7**  **H Tube Exchanger A sm,**  **H Tube Al**  **uminum- Mn** 

# # **0.1075 lb #**  **Deburred Exchanger**  **- 30xx As**  **m, Deburred 8**  **H Tube Exchanger A sm,**  **H Tube 1**  **Al uminum- Mn**  **# 0.1075 lb**  **# 0.1075 lb**  **Extruded Exchanger**  **- 30xx As**  **m, Extruded 9**  H Tube Exchanger Asm, H Tube **1** Commodity **# 0.1075 lb**  **# 0.1075 lb**  Material Exchanger Pricing Asm, Material **7 H Fin, Exchanger A**  **sm, Roll H Fin,**  **1 Al**  **uminum- Mn #**  **0.0346 lb #**  **0.0346 lb Formed**  **Exchanger - 30xx**  **As m, Roll**  **Formed 8**  H Fin, Exchanger Asm, H Fin, **1** Aluminum- Mn - **# 0.0346 lb**  **# 0.0346 lb**  Material Exchanger 30xx - Clad Asm, Material **7 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Deburred**  **Exchanger - 30xx**  **As m, Deburred**  **8 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Extruded**  **Exchanger - 30xx**  **As m, Extruded**  **9** H Tube Exchanger Asm, H Tube **1** Commodity **# 0.1075 lb**  **# 0.1075 lb**  Material Exchanger Pricing Asm, Material **7 H Fin, Exchanger A**  **sm, Roll H Fin,**  **1 Al**  **uminum- Mn #**  **0.0346 lb #**  **0.0346 lb Formed**  **Exchanger - 30xx**  **As m, Roll**  **Formed 8**  H Fin, Exchanger Asm, H Fin, **1** Aluminum- Mn - **# 0.0346 lb**  **# 0.0346 lb**  Material Exchanger 30xx - Clad Asm, Material **7 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Deburred**  **Exchanger - 30xx**  **As m, Deburred**  **8 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Extruded**  **Exchanger - 30xx**  **As m, Extruded**  **9** H Tube Exchanger Asm, H Tube **1** Commodity **# 0.1075 lb**  **# 0.1075 lb**  Material Exchanger Pricing Asm, Material

# Design Profit ®

Page 9 of # Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**
**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost Weight**  **Piece Cost Weight (Total)** 

**(Total) 7**  **H Fin, Exchanger A sm, Roll**  **H Fin, Al**  **uminum- Mn** 

# # **0.0346 lb #**  **Formed Exchanger**  **- 30xx As**  **m, Roll Formed**  **8** H Fin, Exchanger Asm, H Fin, **1** Aluminum- Mn - **# 0.0346 lb**  **# 0.0346 lb**  Material Exchanger 30xx - Clad Asm, Material **7 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Deburred**  **Exchanger - 30xx**  **As m, Deburred**  **8 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Extruded**  **Exchanger - 30xx**  **As m, Extruded**  **9** H Tube Exchanger Asm, H Tube **1** Commodity **# 0.1075 lb**  **# 0.1075 lb**  Material Exchanger Pricing Asm, Material **7 H Fin, Exchanger A**  **sm, Roll H Fin,**  **1 Al**  **uminum- Mn #**  **0.0346 lb #**  **0.0346 lb Formed**  **Exchanger - 30xx**  **As m, Roll**  **Formed 8**  H Fin, Exchanger Asm, H Fin, **1** Aluminum- Mn - **# 0.0346 lb**  **# 0.0346 lb**  Material Exchanger 30xx - Clad Asm, Material **7 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Deburred**  **Exchanger - 30xx**  **As m, Deburred**  **8 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Extruded**  **Exchanger - 30xx**  **As m, Extruded**  **9** H Tube Exchanger Asm, H Tube **1** Commodity **# 0.1075 lb**  **# 0.1075 lb**  Material Exchanger Pricing Asm, Material **7 H Fin, Exchanger A**  **sm, Roll H Fin,**  **1 Al**  **uminum- Mn #**  **0.0346 lb #**  **0.0346 lb Formed**  **Exchanger - 30xx**  **As m, Roll**  **Formed 8**  H Fin, Exchanger Asm, H Fin, **1** Aluminum- Mn - **# 0.0346 lb**  **# 0.0346 lb**  Material Exchanger 30xx - Clad Asm, Material **7 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Deburred**  **Exchanger - 30xx**  **As m, Deburred** 


# Design Profit

®

# Page # of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**
**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost Weight**  **Piece Cost Weight (Total)** 

**(Total) 8**  **H Tube Exchanger A sm,**  **H Tube Al**  **uminum- Mn** 

# 0.1075 lb **Extruded Exchanger**  **- 30xx As**  **m, Extruded 9**  H Tube Exchanger Asm, H Tube **1** Commodity **# 0.1075 lb**  **# 0.1075 lb**  Material Exchanger Pricing Asm, Material **7 H Fin, Exchanger A**  **sm, Roll H Fin,**  **1 Al**  **uminum- Mn #**  **0.0346 lb #**  **0.0346 lb Formed**  **Exchanger - 30xx**  **As m, Roll**  **Formed 8**  H Fin, Exchanger Asm, H Fin, **1** Aluminum- Mn - **# 0.0346 lb**  **# 0.0346 lb**  Material Exchanger 30xx - Clad Asm, Material **7 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Deburred**  **Exchanger - 30xx**  **As m, Deburred**  **8 H Tube Exchanger A**  **sm, H Tube**  **1 Al**  **uminum- Mn #**  **0.1075 lb #**  **0.1075 lb Extruded**  **Exchanger - 30xx**  **As m, Extruded**  **9** H Tube Exchanger Asm, H Tube **1** Commodity **# 0.1075 lb**  **# 0.1075 lb**  Material Exchanger Pricing Asm, Material **6 H LH Outboard Tank,**  **H LH Outboard 1**  **# 0.1813 lb**  **# 0.1813 lb**  **Exchanger Tank,**  **Exchanger 7**  **H LH Outboard Tank, H LH Outboard**  **1 Al**  **-Mn - 30xx - #**  **0.0677 lb #**  **0.0677 lb Exchanger, Stamped**  **Tank, Clad**  **Exchanger, Stamped**  **8** H LH Outboard Tank, H LH Outboard **1** Al-Mn - 30xx - **# 0.0677 lb**  **# 0.0677 lb**  Exchanger, Material Tank, Clad Exchanger, Material **7 H Tank Endcap, Exchanger**  **H Tank 2**  **Al -Mn - 30xx -**  **# 0.0057 lb**  **# 0.0114 lb**  **Endcap, Clad**  **Exchanger 8**  H Tank Endcap, Exchanger, H Tank Endcap, **1** Al-Mn - 30xx - **# 0.0057 lb**  **# 0.0114 lb**  Material Exchanger, Clad Material **7 H Inboard Tank, Exchanger,**  **H Inboard 1**  **Al -Mn - 30xx -**  **# 0.0669 lb**  **# 0.0669 lb**  **Stamping Tank,**  **Clad Exchanger,**  **Stamping** 

# Design Profit

®

# Page # of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**
**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost Weight**  **Piece Cost Weight (Total)** 

**(Total)** 8 H Inboard Tank, Exchanger, H Inboard Tank, Al-Mn - 30xx - 

# 0.0669 lb Material Exchanger, Clad Material **7 H Return Tube, Exchanger**  **H Return Tube, 1**  **Al uminum- Mn**  **# 0.0353 lb**  **# 0.0353 lb**  **As m**  **Exchanger - 30xx**  **As m**  **8 H Return Tube, Exchanger,**  **H Return Tube, 1**  **Al uminum- Mn**  **# 0.0353 lb**  **# 0.0353 lb**  **Material Exchanger,**  **- 30xx Material**  **6 H LH Mounting Bracket,**  **H LH Mounting 1**  **Al uminum- Mn**  **# 0.0288 lb**  **# 0.0288 lb**  **Exchanger, Deburred Bracket,**  **- 30xx Exchanger,**  **Deburred 7**  **H LH Mounting Bracket, H LH Mounting**  **1 Al**  **uminum- Mn #**  **0.0288 lb #**  **0.0288 lb Exchanger, Machined**  **Bracket, - 30xx**  **Exchanger, Machined**  **8 H LH Mounting Bracket,**  **H LH Mounting 1**  **Al uminum- Mn**  **# 0.0288 lb**  **# 0.0288 lb**  **Exchanger, Extruded Bracket,**  **- 30xx Exchanger,**  **Extruded 9**  H LH Mounting Bracket, H LH Mounting **1** Commodity **# 0.0288 lb**  **# 0.0288 lb**  Exchanger, Material Bracket, Pricing Exchanger, Material **6 H Locator Bracket,**  **H Locator 1**  **Al uminum- Mn**  **# 0.0299 lb**  **# 0.0299 lb**  **Exchanger, Deburred Bracket,**  **- 30xx Exchanger,**  **Deburred 7**  **H Locator Bracket, H Locator**  **1 Al**  **uminum- Mn #**  **0.0299 lb #**  **0.0299 lb Exchanger, Extruded**  **Bracket, - 30xx**  **Exchanger, Extruded**  **8** H Locator Bracket, Exchanger, H Locator **1** Commodity **# 0.0299 lb**  **# 0.0299 lb**  Material Bracket, Pricing Exchanger, Material **6 H RH Outboard Tank,**  **H RH 1**  **# 0.1460 lb**  **# 0.1460 lb**  **Exchanger Outboard**  **Tank, Exchanger** 



# Design Profit

®

# Page # of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**
**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost Weight**  **Piece Cost Weight (Total)** 

**(Total) 7**  **H Inboard Tank, Exchanger, H Inboard**  **Al -Mn - 30xx -**  

# # **0.0669 lb #**  **Stamping Tank,**  **Clad Exchanger,**  **Stamping 8**  H Inboard Tank, Exchanger, H Inboard Tank, **1** Al-Mn - 30xx - **# 0.0669 lb**  **# 0.0669 lb**  Material Exchanger, Clad Material **7 H Tank Endcap, Exchanger**  **H Tank 2**  **Al -Mn - 30xx -**  **# 0.0057 lb**  **# 0.0114 lb**  **Endcap, Clad**  **Exchanger 8**  H Tank Endcap, Exchanger, H Tank Endcap, **1** Al-Mn - 30xx - **# 0.0057 lb**  **# 0.0114 lb**  Material Exchanger, Clad Material **7 H RH Outboard Tank,**  **H RH 1**  **Al -Mn - 30xx -**  **# 0.0677 lb**  **# 0.0677 lb**  **Exchanger, Stamped Outboard**  **Clad Tank,**  **Exchanger, Stamped**  **8** H RH Outboard Tank, H RH Outboard **1** Al-Mn - 30xx - **# 0.0677 lb**  **# 0.0677 lb**  Exchanger, Material Tank, Clad Exchanger, Material **6 H Fluid Pipe Fitting**  **H Fluid Pipe 1**  **Al uminum- Mn**  **# 0.0594 lb**  **# 0.0594 lb**  **H Fluid Pipe Fitting H Fluid Pipe**  **uminum- Mn 0.0594 lb**  **0.0594 lb Exchanger A** 

**sm, Extruded Fitting**  **- 30xx**

**Exchanger As**  **m, Extruded 7**  **H Fluid Pipe Fitting H Fluid Pipe**  **1 Al**  **uminum- Mn #**  **0.0594 lb #**  **0.0594 lb Exchanger A** 

**sm, Machined Fitting**  **- 30xx**

**Exchanger As**  **m, Machined**  **8 H Fluid Pipe Fitting**  **H Fluid Pipe 1**  **Al uminum- Mn**  **# 0.0594 lb**  **# 0.0594 lb**  **Exchanger A**

**sm, Extruded Fitting**  **- 30xx**

**Exchanger As**  **m, Machined-1**  **9** H Fluid Pipe Fitting Exchanger H Fluid Pipe **1** Commodity **# 0.0594 lb**  **# 0.0594 lb**  Asm, Material Fitting Price Exchanger Asm, Material

# Design Profit ®

Page # of # Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**
**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost Weight**  **Piece Cost Weight (Total)** 

**(Total) H RH Mounting Bracket,**  **H RH** 

# 1 **Al uminum- Mn**  

# # **0.0293 lb 0.0293 lb**  **Exchanger, Deburred Mounting**  **- 30xx Bracket,**  **Exchanger, Deburred**  **7 H RH Mounting Bracket,**  **H RH 1**  **Al uminum- Mn**  **# 0.0293 lb**  **# 0.0293 lb**  **Exchanger, Machined Mounting**  **- 30xx Bracket,**  **Exchanger, Machined**  **8 H RH Mounting Bracket,**  **H RH 1**  **Al uminum- Mn**  **# 0.0293 lb**  **# 0.0293 lb**  **Exchanger, Extruded Mounting**  **- 30xx Bracket,**  **Exchanger, Extruded**  **9** H RH Mounting Bracket, H RH Mounting **1** Commodity **# 0.0293 lb**  **# 0.0293 lb**  Exchanger, Material Bracket, Pricing Exchanger, Material **6 H Locator Bracket,**  **H Locator 1**  **Al uminum- Mn**  **# 0.0299 lb**  **# 0.0299 lb**  **Exchanger, Deburred Bracket,**  **- 30xx Exchanger,**  **Deburred 7**  **H Locator Bracket, H Locator**  **1 Al**  **uminum- Mn #**  **0.0299 lb #**  **0.0299 lb Exchanger, Extruded**  **Bracket, - 30xx**  **Exchanger, Extruded**  **8** H Locator Bracket, Exchanger, H Locator **1** Commodity **# 0.0299 lb**  **# 0.0299 lb**  Material Bracket, Pricing Exchanger, Material 2 H Label, Exchanger Asm H Label, 1 Commodity # 0.0001 lb # 0.0001 lb Exchanger Asm Pricing **1 H Tube & Hose A** 

**sm, Trans H Tube & Hose**  **1 #**  **0.4584 lb #**  **0.4584 lb Cooler A** 

**sm As**  **m, Trans Cooler A** 

**sm 2**  **H Tube A**

**sm, Trans Cooler H Tube A**  **sm, 1**  **# 0.1740 lb**  **# 0.1740 lb**  **As m**  **Trans Cooler As**  **m 3**  **H Tube A**

**sm, Trans Cooler H Tube A**  **sm, 1**  **Al uminum- Mn**  **# 0.1740 lb**  **# 0.1740 lb**  **As m, Pressed**  **Trans Cooler - 30xx**  **As m, Pressed** 


# Design Profit

®

# Page # of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**
**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost Weight**  **Piece Cost Weight (Total)** 

**(Total) H Pipe, Tube A** 

**sm, Trans H Pipe, Tube**  

# 1 **# 0.1001 lb**  **# 0.1001 lb**  **Cooler As**  **m, Trans Cooler**  **5** H Pipe, Tube Asm, Trans H Pipe, Tube **1** Commodity **# 0.1001 lb**  **# 0.1001 lb**  Cooler, Material Asm, Trans Pricing Cooler, Material **4 H Fitting, Tube A** 

**sm, Washed H Fitting, Tube**  **1 #**  **0.0739 lb #**  **0.0739 lb**

**As m, Washed**  **5 H Fitting, Tube A** 

**sm, H Fitting, Tube**  **1 #**  **0.0739 lb #**  **0.0739 lb Deburred**  **As m, Deburred**  **6 H Fitting, Tube A**  **sm, H Fitting, Tube**  **1 #**  **0.0739 lb #**  **0.0739 lb Machined**  **As m,**  **Machined 7**  **H Fitting, Tube A sm,**  **H Fitting, Tube 1**  **# 0.0739 lb**  **# 0.0739 lb**  **Extruded As**  **m, Extruded 8**  H Fitting, Tube Asm, Material H Fitting, Tube **1 #**  **0.0739 lb #**  **0.0739 lb** Asm, Material 2 H O-Ring, 18.5 x 2.5 mm H O-Ring, 18.5 1 Commodity # 0.0007 lb # 0.0007 lb x 2.5 mm Pricing

**2 H Rubber Tube, 17 mm Diam**  **H Rubber 1**  **EDPM #**  **0.0080 lb #**  **0.0080 lb Tube, 17 mm**  **Diam 3**  H Rubber Tube, 17 mm Diam, H Rubber Tube, **1** EDPM **# 0.0080 lb**  **# 0.0080 lb**  Material 17 mm Diam, Material 2 H Heat Shrink Fabric Tube, 21 H Heat Shrink 1 Commodity # 0.0054 lb # 0.0054 lb mm Diam Fabric Tube, 21 Pricing mm Diam **2 H Hose A** 

**sm, Trans Cooler H Hose A**  **sm, 1**  **# 0.2703 lb**  **# 0.2703 lb**  **Trans Cooler 3**  **H Hose A**

**sm, Trans Cooler H Hose, Trans**  **1 EPDM**  **# 0.2270 lb**  **# 0.2270 lb**  **Cooler 4**  H Hose, Trans Cooler, Material H Hose, Trans **1** EPDM **# 0.2270 lb**  **# 0.2270 lb**  Cooler, Material 3 H Oetiker Clamp, Medium H Oetiker 1 Commodity # 0.0177 lb # 0.0177 lb (26.5mm) Clamp, Medium Pricing (26.5mm) 3 H Hose Clamp, Medium H Hose Clamp, 1 Commodity # 0.0256 lb # 0.0256 lb (27mm) Medium Pricing (27mm)

# Design Profit ®

Page # of # Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Level Sy**  **mbol Name Number**  **Qty Material**  **Piece Cost Weight**  **Piece Cost Weight (Total)** 

**(Total)** H Bolt, Line Asm to Exchanger H Bolt, Line 

# 1 Commodity 

# # 0.0384 lb # 0.0384 lb Asm to Pricing Exchanger 0 H Bolt, Trans Cooler to FEM H Bolt, Trans 1 Commodity # 0.0230 lb # 0.0230 lb Cooler to FEM Pricing 0 H Bolt, Trans Cooler to FEM H Bolt, Trans 1 Commodity # 0.0230 lb # 0.0230 lb Cooler to FEM Pricing **0 H Trans Cooler Line A**  **sm, E H Trans Cooler**  **1 #**  **0.5914 lb #**  **0.5914 lb Motor Cooling**  **Line A sm, E**  **Motor Cooling 1**  **H Trans Cooler Line, E Motor H Trans Cooler**  **1 #**  **0.5426 lb #**  **0.5426 lb Cooling**  **Line, E Motor Cooling**  **2** H Trans Cooler Line, E Motor H Trans Cooler **1 #**  **0.5426 lb #**  **0.5426 lb** Cooling, Material Line, E Motor Cooling, Material 1 H Hose Clamp, Medium H Hose Clamp, 1 Commodity # 0.0200 lb # 0.0200 lb (24mm) Medium Pricing (24mm) 1 H Hose Clamp, Medium H Hose Clamp, 1 Commodity # 0.0256 lb # 0.0256 lb (27mm) Medium Pricing (27mm) 1 H Strap On Christmas Tree H Strap On 1 Commodity # 0.0032 lb # 0.0032 lb Clip (#30) Christmas Tree Pricing Clip (#30) 

# Assembly Totals 

# Report Totals **Preassembled Totals**

**An aly**  **zed Subs:** # 

# Piece Cost (Total): **Analyzed Subs: Unanaly**  **zed Subs:** 2 

# Unanalyzed Subs: 

# Weight (Total): 6.5616 lb

**Parts:** # 

# Parts: **Fasteners:** # 

# Fasteners: **Parts+Unanaly**

**zed:** # 

# Parts+Unanalyzed:



# Design Profit

®

# Page # of #

Copyright 2010 © Design Profit, Inc.

# 2.8849 lb

**0.1075 lb**

**0.1075 lb**

**0.1075 lb**

**0.0346 lb**

**0.0346 lb**



# 0.1075 lb

**0.1075 lb**

**0.1075 lb**

**0.0346 lb**

**0.0346 lb**

**0.1075 lb**

# Weight (Total)

**0.1075 lb**

**0.1075 lb**

**0.0346 lb**

**0.0346 lb**

**0.1075 lb**

**0.1075 lb**

**0.1075 lb**



# 0.0346 lb

**0.0346 lb**

**0.1075 lb**

**0.1075 lb**

**0.1075 lb**

**0.0346 lb**

# Weight (Total)

0.0346 lb

**0.1075 lb**

**0.1075 lb**

**0.1075 lb**

**0.0346 lb**

**0.0346 lb**

**0.1075 lb**



# 0.1075 lb

**0.1075 lb**

**0.0346 lb**

**0.0346 lb**

**0.1075 lb**

**0.1075 lb**

# Weight (Tota

0.1075 lb

**0.0346 lb**

**0.0346 lb**

**0.1075 lb**

**0.1075 lb**

**0.1075 lb**

**0.0346 lb**



# 0.0346 lb

**0.1075 lb**

**0.1075 lb**

**0.1075 lb**

**0.0346 lb**

**0.0346 lb**

# Weight (Total)

**0.1075 lb**

**0.1075 lb**

**0.1075 lb**

**0.0346 lb**

**0.0346 lb**

**0.1075 lb**

**0.1075 lb**



# 0.1075 lb

**0.0346 lb**

**0.0346 lb**

**0.1075 lb**

**0.1075 lb**

**0.1075 lb**

# Weight (Total)

**0.0346 lb**

**0.0346 lb**

**0.1075 lb**

**0.1075 lb**

**0.1075 lb**

**0.0346 lb**

**0.0346 lb**



# 0.1075 lb

**0.1075 lb**

**0.1075 lb**

**0.0346 lb**

**0.0346 lb**

**0.1075 lb**

# Weight (Total)

**0.1075 lb**

**0.1075 lb**

**0.0346 lb**

**0.0346 lb**

**0.1075 lb**

**0.1075 lb**

**0.1075 lb**



# 0.0677 lb

**0.0677 lb**

**0.0114 lb**

**0.0114 lb**

**0.0669 lb**

# Weight (Total)

0.0669 lb

**0.0353 lb**

**0.0353 lb**

**0.0288 lb**

**0.0288 lb**

**0.0288 lb**



# 0.0299 lb

**0.0299 lb**

# Weight (Total)

**0.0669 lb**

**0.0669 lb**

**0.0114 lb**

**0.0114 lb**

**0.0677 lb**

**0.0677 lb**



# 0.0594 lb

**0.0594 lb**

**0.0594 lb**

# 0.0293 lb

**0.0293 lb**

**0.0293 lb**

**0.0293 lb**



# 0.0299 lb

**0.0299 lb**

# 0.1001 lb

**0.0739 lb**

**0.0739 lb**

# Assembly Report

**H Trans & DC-DC Cooling Sy stem** 

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $83.31 Tool H Trans & DC-DC First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 Cooling System

- - - Install Trans Coolant Bottle Asm

- - - - - - $43.52 Subassembly H Trans & DC-DC H Bottle Asm w/Hose, Trans H Bottle Asm 3.0000 sec 3.0000 sec

- $0.07 1 Cooling System Coolant w/Hose, Trans Coolant $43.52 Tool H Bottle Asm First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 w/Hose, Trans Coolant $43.52 Subassembly H Bottle Asm H Bottle Asm, Trans Coolant H Bottle Asm, 3.0000 sec 3.0000 sec

- $0.04 1 w/Hose, Trans Trans Coolant Coolant $43.52 Tool H Bottle Asm, First Fixture 0.0000 sec 0.0000 sec $0.00 $0.00 1 Trans Coolant $43.52 Subassembly H Bottle Asm, H Bottle, Trans Coolant H Bottle, Trans 3.0000 sec 3.0000 sec

- $0.04 1 Trans Coolant Coolant $43.52 Tool H Bottle, Trans Press 0.0000 sec 0.0000 sec $0.00 $0.00 1 Coolant 

# $43.52 Subassembly H Bottle, Trans H Bottle, Trans Coolant, W elded H Bottle, Trans 3.0000 sec 3.0000 sec

- $0.04 1 Coolant Coolant, W elded $43.52 Tool H Bottle, Trans Vibration W elder 0.0000 sec 0.0000 sec $0.00 $0.00 1 Coolant, W elded ###### P.-P. Part H Bottle, Trans H Bottle Bottom, Trans Coolant, H Bottle Bottom, 3.0000 sec 3.0000 sec

- $0.04 1 Coolant, W elded Molded Trans Coolant, Molded ###### Tool H Bottle Bottom, Inj Mold Machine 1500-3000 Ton 0.0000 sec 0.0000 sec $0.00 $0.00 1 Trans Coolant, Molded ###### Part H Bottle Bottom, H Bottle Bottom, Trans Coolant, H Bottle Bottom, 0.0000 sec **5.3670 sec** $0.40 $0.23 1 Trans Coolant, Material Trans Coolant, Molded Material

- - - Raw Material Req 0.461 lbs from

- - **-** - - - Cost Sheet

- - - 10 Cavity Mold

- - **-** - - -

- - - Box Size 248mm L x 172mm W x - - **-** - - - 134mm H


# Design Profit ®

# Page 1 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $90.59 P.-P. Part H Bottle, Trans H Bottle Top, Trans Coolant, H Bottle Top, 5.0000 sec **5.0000 sec**

- $0.06 1 Coolant, W elded Molded Trans Coolant, Molded $90.59 Tool H Bottle Top, Inj Molding Machine 800-1500 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Trans Coolant, Ton Molded $90.59 Part H Bottle Top, H Bottle Top, Trans Coolant, H Bottle Top, 0.0000 sec **4.7770 sec** $0.18 $0.12 1 Trans Coolant, Material Trans Coolant, Molded Material

- - - Raw Material Req 0.205 lbs from

- - **-** - - - Cost Sheet

- - - 10 Cavity Mold

- - **-** - - -

- - - Box Size 248mm L x 165mm W x - - **-** - - - 24mm H $43.52 Fastening H Bottle, Trans Vibration W eld 3.0000 sec **3.0000 sec** $0.00 $0.04 1 Coolant, W elded $44.85 P.-P. Part H Bottle, Trans H Tube, Trans Coolant Bottle H Tube, Trans 5.0000 sec **5.0000 sec**

- $0.06 1 Coolant Coolant Bottle $44.85 Tool H Tube, Trans Tube Cutter 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Coolant Bottle $44.85 Part H Tube, Trans H Tube, Trans Coolant Bottle, H Tube, Trans 0.0000 sec **0.0000 sec** $0.02 $0.00 1 Coolant Bottle Material Coolant Bottle, 

# Material $44.85 Operation H Tube, Trans Clamp Part 3.0000 sec **3.0000 sec** $0.00 $0.04 1 Coolant Bottle $44.85 Material Mod. H Tube, Trans Cut to Length 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Coolant Bottle $44.85 Operation H Tube, Trans Unclamp Part 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Coolant Bottle

- - - Raw Mat: 0.0142 lbs SS304 (12D

- - **-** - - - x 0.53W all)mm

- - - Box size of finished part

- - **-** - - - 0.53Dmm x 41.3Lmm $43.52 Fastening H Bottle, Trans Press Together 3.0000 sec **3.0000 sec** $0.00 $0.04 1 Coolant $43.52 P.-P. Part H Bottle Asm, H Cap, Trans Coolant Bottle H Cap, Trans 7.0000 sec **7.0000 sec**

- $0.08 1 Trans Coolant Coolant Bottle $43.52 Tool H Cap, Trans Paint Machine 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Coolant Bottle $28.80 P.-P. Part H Cap, Trans H Cap, Trans Coolant Bottle, H Cap, Trans 3.0000 sec **3.0000 sec**

- $0.04 1 Coolant Bottle Molded Coolant Bottle, Molded 

# Design Profit ®

# Page 2 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $28.80 Tool H Cap, Trans Injection Molding Machine 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Coolant Bottle, 200-400 Ton Molded $28.80 Part H Cap, Trans H Cap, Trans Coolant Bottle, H Cap, Trans 0.0000 sec **1.7910 sec** $0.03 $0.01 1 Coolant Bottle, Material Coolant Bottle, Molded Material

- - - Raw Material Req 0.038 lbs from

- - **-** - - - Cost Sheet

- - - 10 Cavity Mold

- - **-** - - -

- - - Box Size 136mm L x 56mm W x - - **-** - - - 37mm H $43.52 Tool H Cap, Trans Stencil 6.0000 sec **6.0000 sec** $0.00 $0.07 1 Coolant Bottle $43.52 Fastening H Cap, Trans Apply Paint 15.0000 sec **15.0000 sec** $0.00 $0.18 1 Coolant Bottle $43.52 Multitouch H Bottle Asm, Grab & Position Cap Retainer Grab & Position 9.0000 sec **9.0000 sec** $0.00 $0.11 1 Trans Coolant Cap Retainer $43.52 Fastening H Bottle Asm, Snap Together 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Trans Coolant $43.52 Part H Bottle Asm, H Label, Trans Cooler Bottle H Label, Trans 9.0000 sec **9.0000 sec** $0.10 $0.11 1 Trans Coolant Cooler Bottle $43.52 Fastening H Bottle Asm, Apply Label 3.0000 sec **3.0000 sec** $0.00 $0.04 1



# Fastening H Bottle Asm, Apply Label 3.0000 sec **3.0000 sec**

Trans Coolant $54.35 Subassembly H Bottle Asm H Hose Asm, Coolant, Trans to H Hose Asm, 6.0000 sec **6.0000 sec**

- $0.07 1 w/Hose, Trans Bottle Coolant, Trans to Coolant Bottle $54.35 Tool H Hose Asm, First Fixture 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Coolant, Trans to Bottle $35.94 P.-P. Part H Hose Asm, H Hose, Coolant, Trans to Bottle, H Hose, Coolant, 3.0000 sec **3.0000 sec**

- $0.05 1 Coolant, Trans to Extruded Trans to Bottle, Bottle Extruded $35.94 Tool H Hose, Coolant, Extruder 32mm Base 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Trans to Bottle, Extruded $35.94 Part H Hose, Coolant, H Hose, Coolant, Trans to Bottle, H Hose, Coolant, 0.0000 sec **3.7659 sec** $0.15 $0.04 1 Trans to Bottle, Material Trans to Bottle, Extruded Material

- - - Box Size 175mmL x 66mmW x - - **-** - - - 29mmH



# Design Profit ®

# Page 3 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $54.35 Part H Hose Asm, H Sheath, (15/16"), Bottle to H Sheath, 6.0000 sec **6.0000 sec** $0.18 $0.09 1 Coolant, Trans to Trans Hose (15/16"), Bottle to Bottle Trans Hose $54.35 Part H Hose Asm, H Hose Clamp, Medium (24mm) H Hose Clamp, 7.0000 sec **7.0000 sec** $0.22 $0.11 1 Coolant, Trans to Medium (24mm) Bottle $54.35 Part H Hose Asm, H Hose Clamp, Medium (22mm) H Hose Clamp, 7.0000 sec **7.0000 sec** $0.21 $0.11 1 Coolant, Trans to Medium (22mm) Bottle $54.35 Tool H Hose Asm, Hand Tool 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Coolant, Trans to Bottle $54.35 Fastening H Hose Asm, Relase Hose Spring Clamp 2.0000 sec **2.0000 sec** $0.00 $0.03 2 Coolant, Trans to Bottle $54.35 Operation H Hose Asm, CDI 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Coolant, Trans to Bottle $43.52 Operation H Bottle Asm Press part 3.0000 sec **3.0000 sec** $0.00 $0.04 1 w/Hose, Trans Coolant $43.52 Tool H Bottle Asm Hand Tool 3.0000 sec **3.0000 sec** $0.00 $0.04 1 

# H Bottle Asm Hand Tool 3.0000 sec **3.0000 sec** w/Hose, Trans Coolant $43.52 Fastening H Bottle Asm Relase Hose Spring Clamp 2.0000 sec **2.0000 sec** $0.00 $0.02 1 w/Hose, Trans Coolant $83.31 Part H Trans & DC-DC H Bolt Trans Coolant Bottle H Bolt Trans 4.0000 sec **4.0000 sec** $0.06 $0.09 1 Cooling System Coolant Bottle $83.31 Tool H Trans & DC-DC Power Tool 4.0000 sec **4.0000 sec** $0.00 $0.09 1 Cooling System $83.31 Fastening H Trans & DC-DC Power Screw 4.0000 sec **4.0000 sec** $0.00 $0.09 1 Cooling System $83.31 Operation H Trans & DC-DC CDI 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Cooling System $83.31 Part H Trans & DC-DC H Nut Trans Coolant Bottle H Nut Trans 4.0000 sec **4.0000 sec** $0.06 $0.09 1 Cooling System Coolant Bottle $83.31 Tool H Trans & DC-DC Power Tool 4.0000 sec **4.0000 sec** $0.00 $0.09 1 Cooling System $83.31 Fastening H Trans & DC-DC Power Screw 4.0000 sec **4.0000 sec** $0.00 $0.09 1 Cooling System


# Design Profit ®

# Page 4 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $83.31 Multitouch H Trans & DC-DC H Hose Coolant Bottle to Trans H Hose Coolant 6.0000 sec **6.0000 sec** $0.00 $0.14 1 Cooling System Bottle to Trans $83.31 Fastening H Trans & DC-DC Press Together 3.0000 sec **3.0000 sec** $0.00 $0.07 1 Cooling System $83.31 Tool H Trans & DC-DC Hand Tool 3.0000 sec **3.0000 sec** $0.00 $0.07 1 Cooling System $83.31 Fastening H Trans & DC-DC Relase Hose Spring Clamp 2.0000 sec **2.0000 sec** $0.00 $0.05 1 Cooling System $83.31 Operation H Trans & DC-DC CDI 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Cooling System

- - - Install Trans Coolant Pump Sub

- - **-** - - - $35.51 Subassembly H Trans & DC-DC H Trans Coolant Pump Sub Asm H Trans Coolant 9.0000 sec **9.0000 sec**

- $0.21 1 Cooling System Pump Sub Asm $35.51 Tool H Trans Coolant First Fixture 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Pump Sub Asm $35.51 Subassembly H Trans Coolant H Trans Coolant Pump w/Mount H Trans Coolant 3.0000 sec **3.0000 sec**

- $0.03 1 Pump Sub Asm Pump w/Mount $35.51 Tool H Trans Coolant First Fixture 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Pump w/Mount $29.69 Subassembly H Trans Coolant H Trans Coolant Pump H Trans Coolant 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Pump w/Mount Pump $16.39 P.-P. Part H Trans Coolant H Isolation Ring, Mount, Coolant H Isolation Ring, 6.0000 sec **6.0000 sec**

- $0.06 1



# P.-P. Part H Trans Coolant H Isolation Ring, Mount, Coolant H Isolation Ring, 6.0000 sec **6.0000 sec**

Pump w/Mount Pump Mount, Coolant Pump $16.39 Tool H Isolation Ring, Injection Molding Machine 55-150 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Mount, Coolant ton Pump $16.39 Part H Isolation Ring, H Isolation Ring, Mount, Coolant H Isolation Ring, 0.0000 sec **3.2560 sec** $0.05 $0.01 1 Mount, Coolant Pump, Material Mount, Coolant Pump Pump, Material

- - - Raw Material Req 0.049 lbs from

- - **-** - - - Cost Sheet

- - - 14 Cavity Mold

- - **-** - - -

- - - Box Size 60mm L x 60mm W x - - **-** - - - 23mm H $35.51 Fastening H Trans Coolant Push In Place 2.0000 sec **2.0000 sec** $0.00 $0.02 1 Pump w/Mount $16.39 P.-P. Part H Trans Coolant H Clamp, Mount, Coolant Pump H Clamp, Mount, 8.0000 sec **8.0000 sec**

- $0.08 1 Pump w/Mount Coolant Pump $16.39 Tool H Clamp, Mount, Injection Molding Machine 55-150 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Coolant Pump ton

# Design Profit ®

Page 5 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $16.39 Part H Clamp, Mount, H Clamp, Mount, Coolant Pump, H Clamp, Mount, 0.0000 sec **1.1810 sec** $0.08 $0.01 1 Coolant Pump Material Coolant Pump, Material

- - - Raw Material Req 0.043 lbs from

- - **-** - - - Cost Sheet

- - - 14 Cavity Mold

- - **-** - - -

- - - Box Size 100mm L x 73mm W x - - **-** - - - 24mm H $35.51 Fastening H Trans Coolant Position Clamp 2.0000 sec **2.0000 sec** $0.00 $0.02 1 Pump w/Mount $35.51 Fastening H Trans Coolant Snap Together 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Pump w/Mount $35.51 Operation H Trans Coolant CDI 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Pump w/Mount $35.51 Subassembly H Trans Coolant H Bracket Asm, Mount, Coolant H Bracket Asm, 6.0000 sec **6.0000 sec**

- $0.06 1 Pump w/Mount Pump Mount, Coolant Pump $35.51 Tool H Bracket Asm, First Fixture 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Mount, Coolant Pump $55.17 P.-P. Part H Bracket Asm, H Bracket, Mount, Coolant Pump H Bracket, Mount, 3.0000 sec **3.0000 sec**

- $0.03 1 Mount, Coolant Coolant Pump 

# Pump $55.17 Tool H Bracket, Mount, First Fixture 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Coolant Pump

- - - E-coat

- - **-** - - - $10.75 P.-P. Part H Bracket, Mount, H Bracket, Mount, Coolant Pump, H Bracket, Mount, 3.0000 sec **3.0000 sec**

- $0.05 1 Coolant Pump Wa shed Coolant Pump, Wa shed $10.75 Tool H Bracket, Mount, Wa sher Duo 400 W ash Rinse & 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Coolant Pump, DRY Wa shed $15.50 P.-P. Part H Bracket, Mount, H Bracket, Mount, Coolant Pump, H Bracket, Mount, 3.0000 sec **3.0000 sec**

- $0.01 1 Coolant Pump, Stamped Coolant Pump, Wa shed Stamped $15.50 Tool H Bracket, Mount, Stamping Press 0-60 Ton 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Coolant Pump, Stamped $15.50 Part H Bracket, Mount, H Bracket, Mount, Coolant Pump, H Bracket, Mount, 0.0000 sec **0.7000 sec** $0.14 $0.00 1 Coolant Pump, Material Coolant Pump, Stamped Material

- - - Blank weight 0.303 lbs

- - **-** - - - 

# Design Profit ®

# Page 6 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)**

- - - 60 Ton Progressive Press

- - **-** - - -

- - - Part Size after stamping (92 L by

- - **-** - - - 87 W by 15 H)mm $10.75 Operation H Bracket, Mount, Load Part 3.0000 sec **3.0000 sec** $0.00 $0.01 1 Coolant Pump, Wa shed $10.75 Operation H Bracket, Mount, Wa sh Part Medium 5.0000 sec **5.0000 sec** $0.00 $0.01 1 Coolant Pump, Wa shed $10.75 Operation H Bracket, Mount, Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.01 1 Coolant Pump, Wa shed $55.17 Operation H Bracket, Mount, Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Coolant Pump $55.17 Operation H Bracket, Mount, Paint Part Small 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Coolant Pump $55.17 Tool H Bracket, Mount, Oven 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Coolant Pump $55.17 Operation H Bracket, Mount, Paint Oven Cure 60.0000 sec **60.0000 sec** $0.00 $0.92 1 Coolant Pump $55.17 Operation H Bracket, Mount, Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Coolant Pump 

# $35.51 Part H Bracket Asm, H Foam Pad, Self Stick, Pump H Foam Pad, Self 7.0000 sec **7.0000 sec** $0.01 $0.07 1 Mount, Coolant Bracket Stick, Pump Pump Bracket $35.51 Fastening H Bracket Asm, Apply Label 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Mount, Coolant Pump $35.51 Fastening H Trans Coolant Snap Together 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Pump w/Mount $54.35 Subassembly H Trans Coolant H Coolant Line Asm, Pump to E H Coolant Line 9.0000 sec **9.0000 sec**

- $0.09 1 Pump Sub Asm Motor Asm, Pump to E Motor $54.35 Tool H Coolant Line First Fixture 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Pump to E Motor $35.94 P.-P. Part H Coolant Line H Coolant Line, Pump to E Motor H Coolant Line, 4.0000 sec **4.0000 sec**

- $0.06 1 Asm, Pump to E Pump to E Motor Motor $35.94 Tool H Coolant Line, Extruder 32mm Base 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Pump to E Motor


# Design Profit ®

# Page 7 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $35.94 Part H Coolant Line, H Coolant Line, Pump to E Motor, H Coolant Line, 0.0000 sec **6.9240 sec** $0.37 $0.07 1 Pump to E Motor Material Pump to E Motor, Material

- - - Box Size 230mmL x 118mmW x - - **-** - - - 86mmH $54.35 Part H Coolant Line H Hose Clamp, Medium (27mm) H Hose Clamp, 7.0000 sec **7.0000 sec** $0.23 $0.11 2 Asm, Pump to E Medium (27mm) Motor $54.35 Tool H Coolant Line Hand Tool 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Asm, Pump to E Motor $54.35 Fastening H Coolant Line Relase Hose Spring Clamp 2.0000 sec **2.0000 sec** $0.00 $0.03 2 Asm, Pump to E Motor $54.35 Operation H Coolant Line CDI 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Asm, Pump to E Motor $35.51 Operation H Trans Coolant Press part 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Pump Sub Asm $35.51 Tool H Trans Coolant Hand Tool 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Pump Sub Asm $35.51 Fastening H Trans Coolant Relase Hose Spring Clamp 2.0000 sec **2.0000 sec** $0.00 $0.02 1



# Fastening H Trans Coolant Relase Hose Spring Clamp 2.0000 sec **2.0000 sec**

Pump Sub Asm $35.51 Operation H Trans Coolant CDI 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Pump Sub Asm $54.35 Subassembly H Trans Coolant H Coolant Line Asm, DC-DC to H Coolant Line 9.0000 sec **9.0000 sec**

- $0.09 1 Pump Sub Asm Pump Asm, DC-DC to Pump $54.35 Tool H Coolant Line First Fixture 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, DC-DC to Pump $35.94 P.-P. Part H Coolant Line H Coolant Line, DC-DC to Pump H Coolant Line, 4.0000 sec **4.0000 sec**

- $0.06 1 Asm, DC-DC to DC-DC to Pump Pump $35.94 Tool H Coolant Line, Extruder 32mm Base 0.0000 sec **0.0000 sec** $0.00 $0.00 1 DC-DC to Pump $35.94 Part H Coolant Line, H Coolant Line, DC-DC to Pump, H Coolant Line, 0.0000 sec **15.9679 sec** $0.55 $0.16 1 DC-DC to Pump Material DC-DC to Pump, Material

- - - Box Size 520mmL x 280mmW x - - **-** - - - 115mmH


# Design Profit ®

# Page 8 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $54.35 Part H Coolant Line H Sheath, (15/16"), Pump to H Sheath, 7.0000 sec **7.0000 sec** $1.19 $0.11 1 Asm, DC-DC to Dc-Dc Module (15/16"), Pump to Pump Dc-Dc Module $54.35 Part H Coolant Line H Hose Clamp, Medium (27mm) H Hose Clamp, 7.0000 sec **7.0000 sec** $0.23 $0.11 2 Asm, DC-DC to Medium (27mm) Pump $54.35 Tool H Coolant Line Hand Tool 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Asm, DC-DC to Pump $54.35 Fastening H Coolant Line Relase Hose Spring Clamp 2.0000 sec **2.0000 sec** $0.00 $0.03 2 Asm, DC-DC to Pump $54.35 Operation H Coolant Line CDI 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Asm, DC-DC to Pump $54.35 Part H Coolant Line H Strap On Hose Clip (#7) H Strap On Hose 11.0000 sec **11.0000 sec** $0.04 $0.17 1 Asm, DC-DC to Clip (#7) Pump $54.35 Fastening H Coolant Line Zip Tie 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Asm, DC-DC to Pump $54.35 Tool H Coolant Line Hand Tool 3.0000 sec **3.0000 sec** $0.00 $0.05 1 

# H Coolant Line Hand Tool 3.0000 sec **3.0000 sec** Asm, DC-DC to Pump $54.35 Fastening H Coolant Line Trim to Length 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Asm, DC-DC to Pump $16.39 P.-P. Part H Coolant Line H Clamp On Christmas Tree Clip H Clamp On 10.0000 sec **10.0000 sec**

- $0.15 1 Asm, DC-DC to Christmas Tree Pump Clip $16.39 Tool H Clamp On Injection Molding Machine 55-150 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Christmas Tree ton Clip $16.39 Part H Clamp On H Clamp On Christmas Tree Clip, H Clamp On 0.0000 sec **1.0920 sec** $0.05 $0.00 1 Christmas Tree Material Christmas Tree Clip Clip, Material

- - - Raw Material Req 0.026 lbs from

- - **-** - - - Cost Sheet

- - - 14 Cavity Mold

- - **-** - - -

- - - Box Size 77mm L x 45mm W x - - **-** - - - 20mm H


# Design Profit ®

# Page 9 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $54.35 Fastening H Coolant Line Snap Together 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Asm, DC-DC to Pump $35.51 Operation H Trans Coolant Press part 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Pump Sub Asm $35.51 Tool H Trans Coolant Hand Tool 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Pump Sub Asm $35.51 Fastening H Trans Coolant Relase Hose Spring Clamp 2.0000 sec **2.0000 sec** $0.00 $0.02 1 Pump Sub Asm $83.31 Part H Trans & DC-DC H Bolt, Trans Coolant Pump H Bolt, Trans 4.0000 sec **4.0000 sec** $0.06 $0.09 2 Cooling System Coolant Pump $83.31 Tool H Trans & DC-DC Power Tool 4.0000 sec **4.0000 sec** $0.00 $0.09 1 Cooling System $83.31 Fastening H Trans & DC-DC Power Screw 4.0000 sec **4.0000 sec** $0.00 $0.09 2 Cooling System $83.31 Multitouch H Trans & DC-DC H Regrab Pump Hose H Regrab Pump 8.0000 sec **8.0000 sec** $0.00 $0.19 1 Cooling System Hose $83.31 Fastening H Trans & DC-DC Press in Xmass Clip 3.0000 sec **3.0000 sec** $0.00 $0.07 1 Cooling System

- - - Install Hose: Pump to DC-DC

- - **-** - - - Module $83.31 Multitouch H Trans & DC-DC H Regrab Pump Hose H Regrab Pump 8.0000 sec **8.0000 sec** $0.00 $0.19 1



# Multitouch H Trans & DC-DC H Regrab Pump Hose H Regrab Pump 8.0000 sec **8.0000 sec**

Cooling System Hose $83.31 Fastening H Trans & DC-DC Press Together 3.0000 sec **3.0000 sec** $0.00 $0.07 1 Cooling System $83.31 Tool H Trans & DC-DC Hand Tool 3.0000 sec **3.0000 sec** $0.00 $0.07 1 Cooling System $83.31 Fastening H Trans & DC-DC Relase Hose Spring Clamp 2.0000 sec **2.0000 sec** $0.00 $0.05 1 Cooling System

- - - Install Hose: Pump to Trans

- - **-** - - - $83.31 Multitouch H Trans & DC-DC H Regrab Pump Hose H Regrab Trans 8.0000 sec **8.0000 sec** $0.00 $0.19 1 Cooling System Hose $83.31 Fastening H Trans & DC-DC Press Together 3.0000 sec **3.0000 sec** $0.00 $0.07 1 Cooling System $83.31 Tool H Trans & DC-DC Hand Tool 3.0000 sec **3.0000 sec** $0.00 $0.07 1 Cooling System $83.31 Fastening H Trans & DC-DC Relase Hose Spring Clamp 2.0000 sec **2.0000 sec** $0.00 $0.05 1 Cooling System $83.31 Operation H Trans & DC-DC CDI 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Cooling System

- - - Space for Printing

- - **-** - - - 

# Design Profit ®

Page 10 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)**

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Install Cooler Asm to FEM (Prior

- - **-** - - - to Radiator Asm) $35.51 Subassembly H Trans & DC-DC H Cooler Asm, Trans & DC-DC H Cooler Asm, 10.0000 sec **10.0000 sec**

- $0.23 1 Cooling System Mod Trans & DC-DC Mod $35.51 Tool H Cooler Asm, First Fixture 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Trans & DC-DC Mod $35.51 Subassembly H Cooler Asm, H Exchanger Asm, Trans Cooler H Exchanger 4.0000 sec **4.0000 sec**

- $0.04 1 Trans & DC-DC Asm Asm, Trans Mod Cooler Asm $35.51 Tool H Exchanger First Fixture 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Trans Cooler Asm $55.17 Subassembly H Exchanger H Exchanger Asm, Trans Cooler, H Exchanger 4.0000 sec **4.0000 sec**

- $0.04 1



# Subassembly H Exchanger H Exchanger Asm, Trans Cooler, H Exchanger 4.0000 sec **4.0000 sec**

Asm, Trans Painted Asm, Trans Cooler Asm Cooler, Painted $55.17 Tool H Exchanger First Fixture 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Trans Cooler, Painted

- - - Spray painted

- - **-** - - - $49.29 Subassembly H Exchanger H Exchanger Asm, Trans Cooler, H Exchanger 4.0000 sec **4.0000 sec**

- $0.06 1 Asm, Trans Wa shed Asm, Trans Cooler, Painted Cooler, W ashed $49.29 Tool H Exchanger Wa sher Med Batch special 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Trans nozzels Cooler, W ashed $46.52 Subassembly H Exchanger H Exchanger Asm, Trans Cooler, H Exchanger 4.0000 sec **4.0000 sec**

- $0.05 1 Asm, Trans Brazed Asm, Trans Cooler, W ashed Cooler, Brazed $46.52 Tool H Exchanger Furnace/Oven 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Trans Cooler, Brazed


# Design Profit ®

Page 11 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $42.18 Subassembly H Exchanger H Exchanger Asm, Assembled H Exchanger 4.0000 sec **4.0000 sec**

- $0.05 1 Asm, Trans Loose Asm, Assembled Cooler, Brazed Loose $42.18 Tool H Exchanger First Fixture 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Assembled Loose $42.18 Subassembly H Exchanger H Cooler Core Asm, Exchanger H Cooler Core 4.0000 sec **4.0000 sec**

- $0.05 1 Asm, Assembled Asm, Ex changer Loose $42.18 Tool H Cooler Core First Fixture 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Ex changer

- - - Stack 17 Tubes & 16 Fins

- - **-** - - - $54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec **3.0000 sec**

- $0.04 1 Asm, Ex changer Deburred Exchanger Asm, Deburred $54.35 Tool H Tube Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Deburred $17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec **4.0000 sec**

- $0.06 1 Exchanger Asm, Extruded Exchanger Asm, Deburred Extruded $17.08 Tool H Tube Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 

# Cut Off Tool 0.0000 sec **0.0000 sec** Exchanger Asm, Extruded $17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec **0.0000 sec** $0.76 $0.00 1 Exchanger Asm, Exchanger Asm, Extruded Material $17.08 Material Mod. H Tube Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Exchanger Asm, Extruded $54.35 Operation H Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Operation H Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger Asm, Deburred

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - 

# Design Profit ®

# Page 12 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)**

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec **6.0000 sec**

- $0.07 1 Asm, Ex changer Formed Asm, Roll Formed $42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Roll Formed $42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec **0.0000 sec** $0.08 $0.00 1 Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock

- - **-** - - - $42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec **0.7969 sec** $0.00 $0.01 1 Asm, Roll Formed

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec **3.0000 sec**

- $0.04 1 Asm, Ex changer Deburred Exchanger Asm, Deburred $54.35 Tool H Tube Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Deburred 

# $17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec **4.0000 sec**

- $0.06 1 Exchanger Asm, Extruded Exchanger Asm, Deburred Extruded $17.08 Tool H Tube Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Extruded $17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec **0.0000 sec** $0.76 $0.00 1 Exchanger Asm, Exchanger Asm, Extruded Material $17.08 Material Mod. H Tube Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Exchanger Asm, Extruded $54.35 Operation H Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred



# Design Profit ®

# Page 13 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $54.35 Operation H Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger Asm, Deburred

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec **6.0000 sec**

- $0.07 1 Asm, Ex changer Formed Asm, Roll Formed $42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Roll Formed $42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec **0.0000 sec** $0.08 $0.00 1 Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock

- - **-** - - - $42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec **0.7969 sec** $0.00 $0.01 1 Asm, Roll Formed

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - 

# Space for Printing $54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec **3.0000 sec**

- $0.04 1 Asm, Ex changer Deburred Exchanger Asm, Deburred $54.35 Tool H Tube Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Deburred $17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec **4.0000 sec**

- $0.06 1 Exchanger Asm, Extruded Exchanger Asm, Deburred Extruded $17.08 Tool H Tube Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Extruded $17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec **0.0000 sec** $0.76 $0.00 1 Exchanger Asm, Exchanger Asm, Extruded Material $17.08 Material Mod. H Tube Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Exchanger Asm, Extruded


# Design Profit ®

Page 14 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $54.35 Operation H Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Operation H Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger Asm, Deburred

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec **6.0000 sec**

- $0.07 1 Asm, Ex changer Formed Asm, Roll Formed $42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Roll Formed $42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec **0.0000 sec** $0.08 $0.00 1 Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock

- - **-** - - - $42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec **0.7969 sec** $0.00 $0.01 1



# Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec **0.7969 sec**

Asm, Roll Formed

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec **3.0000 sec**

- $0.04 1 Asm, Ex changer Deburred Exchanger Asm, Deburred $54.35 Tool H Tube Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Deburred $17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec **4.0000 sec**

- $0.06 1 Exchanger Asm, Extruded Exchanger Asm, Deburred Extruded $17.08 Tool H Tube Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Extruded


# Design Profit ®

Page 15 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec **0.0000 sec** $0.76 $0.00 1 Exchanger Asm, Exchanger Asm, Extruded Material $17.08 Material Mod. H Tube Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Exchanger Asm, Extruded $54.35 Operation H Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Operation H Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger Asm, Deburred

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec **6.0000 sec**

- $0.07 1 Asm, Ex changer Formed Asm, Roll Formed 

# $42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Roll Formed $42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec **0.0000 sec** $0.08 $0.00 1 Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock

- - **-** - - - $42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec **0.7969 sec** $0.00 $0.01 1 Asm, Roll Formed

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec **3.0000 sec**

- $0.04 1 Asm, Ex changer Deburred Exchanger Asm, Deburred $54.35 Tool H Tube Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Deburred


# Design Profit ®

Page 16 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec **4.0000 sec**

- $0.06 1 Exchanger Asm, Extruded Exchanger Asm, Deburred Extruded $17.08 Tool H Tube Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Extruded $17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec **0.0000 sec** $0.76 $0.00 1 Exchanger Asm, Exchanger Asm, Extruded Material $17.08 Material Mod. H Tube Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Exchanger Asm, Extruded $54.35 Operation H Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Operation H Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger Asm, Deburred

- - - Space for Printing

- - **-** - - - 

# Space for Printing

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec **6.0000 sec**

- $0.07 1 Asm, Ex changer Formed Asm, Roll Formed $42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Roll Formed $42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec **0.0000 sec** $0.08 $0.00 1 Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock

- - **-** - - - $42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec **0.7969 sec** $0.00 $0.01 1 Asm, Roll Formed

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - 

# Design Profit ®

Page 17 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec **3.0000 sec**

- $0.04 1 Asm, Ex changer Deburred Exchanger Asm, Deburred $54.35 Tool H Tube Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Deburred $17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec **4.0000 sec**

- $0.06 1 Exchanger Asm, Extruded Exchanger Asm, Deburred Extruded $17.08 Tool H Tube Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Extruded $17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec **0.0000 sec** $0.76 $0.00 1 Exchanger Asm, Exchanger Asm, Extruded Material $17.08 Material Mod. H Tube Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Exchanger Asm, Extruded $54.35 Operation H Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.05 1



# Material Mod. Debur/Tumble 3.0000 sec **3.0000 sec**

Exchanger Asm, Deburred $54.35 Operation H Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger Asm, Deburred

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec **6.0000 sec**

- $0.07 1 Asm, Ex changer Formed Asm, Roll Formed $42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Roll Formed $42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec **0.0000 sec** $0.08 $0.00 1 Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock

- - **-** - - - $42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec **0.7969 sec** $0.00 $0.01 1 Asm, Roll Formed 

# Design Profit ®

Page 18 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)**

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec **3.0000 sec**

- $0.04 1 Asm, Ex changer Deburred Exchanger Asm, Deburred $54.35 Tool H Tube Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Deburred $17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec **4.0000 sec**

- $0.06 1 Exchanger Asm, Extruded Exchanger Asm, Deburred Extruded $17.08 Tool H Tube Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Extruded $17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec **0.0000 sec** $0.76 $0.00 1 Exchanger Asm, Exchanger Asm, Extruded Material $17.08 Material Mod. H Tube Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Exchanger Asm, Extruded 

# $54.35 Operation H Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Operation H Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger Asm, Deburred

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec **6.0000 sec**

- $0.07 1 Asm, Ex changer Formed Asm, Roll Formed $42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Roll Formed


# Design Profit ®

# Page 19 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec **0.0000 sec** $0.08 $0.00 1 Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock

- - **-** - - - $42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec **0.7969 sec** $0.00 $0.01 1 Asm, Roll Formed

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec **3.0000 sec**

- $0.04 1 Asm, Ex changer Deburred Exchanger Asm, Deburred $54.35 Tool H Tube Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Deburred $17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec **4.0000 sec**

- $0.06 1 Exchanger Asm, Extruded Exchanger Asm, Deburred Extruded $17.08 Tool H Tube Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Extruded $17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec **0.0000 sec** $0.76 $0.00 1 

# H Tube Exchanger Asm, Material 0.0000 sec **0.0000 sec** Exchanger Asm, Exchanger Asm, Extruded Material $17.08 Material Mod. H Tube Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Exchanger Asm, Extruded $54.35 Operation H Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Operation H Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger Asm, Deburred

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - 

# Design Profit ®

Page 20 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec **6.0000 sec**

- $0.07 1 Asm, Ex changer Formed Asm, Roll Formed $42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Roll Formed $42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec **0.0000 sec** $0.08 $0.00 1 Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock

- - **-** - - - $42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec **0.7969 sec** $0.00 $0.01 1 Asm, Roll Formed

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec **3.0000 sec**

- $0.04 1 Asm, Ex changer Deburred Exchanger Asm, Deburred $54.35 Tool H Tube Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Deburred $17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec **4.0000 sec**

- $0.06 1 Exchanger Asm, Extruded Exchanger Asm, Deburred Extruded 

# $17.08 Tool H Tube Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Extruded $17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec **0.0000 sec** $0.76 $0.00 1 Exchanger Asm, Exchanger Asm, Extruded Material $17.08 Material Mod. H Tube Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Exchanger Asm, Extruded $54.35 Operation H Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Operation H Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger Asm, Deburred

- - - Space for Printing

- - **-** - - - 

# Design Profit ®

Page 21 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)**

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec **6.0000 sec**

- $0.07 1 Asm, Ex changer Formed Asm, Roll Formed $42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Roll Formed $42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec **0.0000 sec** $0.08 $0.00 1 Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock

- - **-** - - - $42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec **0.7969 sec** $0.00 $0.01 1 Asm, Roll Formed

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec **3.0000 sec**

- $0.04 1 Asm, Ex changer Deburred Exchanger Asm, Deburred $54.35 Tool H Tube Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 

# Deburing Equipment 0.0000 sec **0.0000 sec** Exchanger Asm, Deburred $17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec **4.0000 sec**

- $0.06 1 Exchanger Asm, Extruded Exchanger Asm, Deburred Extruded $17.08 Tool H Tube Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Extruded $17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec **0.0000 sec** $0.76 $0.00 1 Exchanger Asm, Exchanger Asm, Extruded Material $17.08 Material Mod. H Tube Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Exchanger Asm, Extruded $54.35 Operation H Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred 

# Design Profit ®

Page 22 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $54.35 Operation H Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger Asm, Deburred

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec **6.0000 sec**

- $0.07 1 Asm, Ex changer Formed Asm, Roll Formed $42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Roll Formed $42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec **0.0000 sec** $0.08 $0.00 1 Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock

- - **-** - - - $42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec **0.7969 sec** $0.00 $0.01 1 Asm, Roll Formed

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - 

# Space for Printing $54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec **3.0000 sec**

- $0.04 1 Asm, Ex changer Deburred Exchanger Asm, Deburred $54.35 Tool H Tube Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Deburred $17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec **4.0000 sec**

- $0.06 1 Exchanger Asm, Extruded Exchanger Asm, Deburred Extruded $17.08 Tool H Tube Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Extruded $17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec **0.0000 sec** $0.76 $0.00 1 Exchanger Asm, Exchanger Asm, Extruded Material $17.08 Material Mod. H Tube Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Exchanger Asm, Extruded


# Design Profit ®

Page 23 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $54.35 Operation H Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Operation H Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger Asm, Deburred

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec **6.0000 sec**

- $0.07 1 Asm, Ex changer Formed Asm, Roll Formed $42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Roll Formed $42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec **0.0000 sec** $0.08 $0.00 1 Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock

- - **-** - - - $42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec **0.7969 sec** $0.00 $0.01 1



# Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec **0.7969 sec**

Asm, Roll Formed

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec **3.0000 sec**

- $0.04 1 Asm, Ex changer Deburred Exchanger Asm, Deburred $54.35 Tool H Tube Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Deburred $17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec **4.0000 sec**

- $0.06 1 Exchanger Asm, Extruded Exchanger Asm, Deburred Extruded $17.08 Tool H Tube Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Extruded


# Design Profit ®

Page 24 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec **0.0000 sec** $0.76 $0.00 1 Exchanger Asm, Exchanger Asm, Extruded Material $17.08 Material Mod. H Tube Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Exchanger Asm, Extruded $54.35 Operation H Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Operation H Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger Asm, Deburred

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec **6.0000 sec**

- $0.07 1 Asm, Ex changer Formed Asm, Roll Formed 

# $42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Roll Formed $42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec **0.0000 sec** $0.08 $0.00 1 Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock

- - **-** - - - $42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec **0.7969 sec** $0.00 $0.01 1 Asm, Roll Formed

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec **3.0000 sec**

- $0.04 1 Asm, Ex changer Deburred Exchanger Asm, Deburred $54.35 Tool H Tube Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Deburred


# Design Profit ®

Page 25 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec **4.0000 sec**

- $0.06 1 Exchanger Asm, Extruded Exchanger Asm, Deburred Extruded $17.08 Tool H Tube Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Extruded $17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec **0.0000 sec** $0.76 $0.00 1 Exchanger Asm, Exchanger Asm, Extruded Material $17.08 Material Mod. H Tube Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Exchanger Asm, Extruded $54.35 Operation H Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Operation H Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger Asm, Deburred

- - - Space for Printing

- - **-** - - - 

# Space for Printing

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec **6.0000 sec**

- $0.07 1 Asm, Ex changer Formed Asm, Roll Formed $42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Roll Formed $42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec **0.0000 sec** $0.08 $0.00 1 Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock

- - **-** - - - $42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec **0.7969 sec** $0.00 $0.01 1 Asm, Roll Formed

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - 

# Design Profit ®

Page 26 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec **3.0000 sec**

- $0.04 1 Asm, Ex changer Deburred Exchanger Asm, Deburred $54.35 Tool H Tube Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Deburred $17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec **4.0000 sec**

- $0.06 1 Exchanger Asm, Extruded Exchanger Asm, Deburred Extruded $17.08 Tool H Tube Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Extruded $17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec **0.0000 sec** $0.76 $0.00 1 Exchanger Asm, Exchanger Asm, Extruded Material $17.08 Material Mod. H Tube Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Exchanger Asm, Extruded $54.35 Operation H Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.05 1



# Material Mod. Debur/Tumble 3.0000 sec **3.0000 sec**

Exchanger Asm, Deburred $54.35 Operation H Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger Asm, Deburred

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec **6.0000 sec**

- $0.07 1 Asm, Ex changer Formed Asm, Roll Formed $42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Roll Formed $42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec **0.0000 sec** $0.08 $0.00 1 Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock

- - **-** - - - $42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec **0.7969 sec** $0.00 $0.01 1 Asm, Roll Formed 

# Design Profit ®

Page 27 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)**

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec **3.0000 sec**

- $0.04 1 Asm, Ex changer Deburred Exchanger Asm, Deburred $54.35 Tool H Tube Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Deburred $17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec **4.0000 sec**

- $0.06 1 Exchanger Asm, Extruded Exchanger Asm, Deburred Extruded $17.08 Tool H Tube Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Extruded $17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec **0.0000 sec** $0.76 $0.00 1 Exchanger Asm, Exchanger Asm, Extruded Material $17.08 Material Mod. H Tube Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Exchanger Asm, Extruded 

# $54.35 Operation H Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Operation H Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger Asm, Deburred

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec **6.0000 sec**

- $0.07 1 Asm, Ex changer Formed Asm, Roll Formed $42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Roll Formed


# Design Profit ®

# Page 28 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec **0.0000 sec** $0.08 $0.00 1 Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock

- - **-** - - - $42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec **0.7969 sec** $0.00 $0.01 1 Asm, Roll Formed

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec **3.0000 sec**

- $0.04 1 Asm, Ex changer Deburred Exchanger Asm, Deburred $54.35 Tool H Tube Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Deburred $17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec **4.0000 sec**

- $0.06 1 Exchanger Asm, Extruded Exchanger Asm, Deburred Extruded $17.08 Tool H Tube Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Extruded $17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec **0.0000 sec** $0.76 $0.00 1 

# H Tube Exchanger Asm, Material 0.0000 sec **0.0000 sec** Exchanger Asm, Exchanger Asm, Extruded Material $17.08 Material Mod. H Tube Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Exchanger Asm, Extruded $54.35 Operation H Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Operation H Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger Asm, Deburred

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - 

# Design Profit ®

Page 29 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $42.18 P.-P. Part H Cooler Core H Fin, Exchanger Asm, Roll H Fin, Exchanger 6.0000 sec **6.0000 sec**

- $0.07 1 Asm, Ex changer Formed Asm, Roll Formed $42.18 Tool H Fin, Exchanger Roll Form Machine 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Roll Formed $42.18 Part H Fin, Exchanger H Fin, Exchanger Asm, Material H Fin, Exchanger 0.0000 sec **0.0000 sec** $0.08 $0.00 1 Asm, Roll Formed Asm, Material

- - - Start with 0.10mm Clad Stock

- - **-** - - - $42.18 Material Mod. H Fin, Exchanger Roll Form Fin 0.7969 sec **0.7969 sec** $0.00 $0.01 1 Asm, Roll Formed

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $54.35 P.-P. Part H Cooler Core H Tube Exchanger Asm, H Tube 3.0000 sec **3.0000 sec**

- $0.04 1 Asm, Ex changer Deburred Exchanger Asm, Deburred $54.35 Tool H Tube Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Deburred $17.08 P.-P. Part H Tube H Tube Exchanger Asm, H Tube 4.0000 sec **4.0000 sec**

- $0.06 1 Exchanger Asm, Extruded Exchanger Asm, Deburred Extruded 

# $17.08 Tool H Tube Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm, Extruded $17.08 Part H Tube H Tube Exchanger Asm, Material H Tube 0.0000 sec **0.0000 sec** $0.76 $0.00 1 Exchanger Asm, Exchanger Asm, Extruded Material $17.08 Material Mod. H Tube Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Exchanger Asm, Extruded $54.35 Operation H Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Material Mod. H Tube Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm, Deburred $54.35 Operation H Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger Asm, Deburred $42.18 Operation H Cooler Core Clamp Part 3.0000 sec **3.0000 sec** $0.00 $0.04 2 Asm, Ex changer 

# Design Profit ®

# Page 30 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $42.18 Operation H Exchanger Clamp Part 3.0000 sec **3.0000 sec** $0.00 $0.04 2 Asm, Assembled Loose $42.18 Subassembly H Exchanger H LH Outboard Tank, Exchanger H LH Outboard 3.0000 sec **3.0000 sec**

- $0.04 1 Asm, Assembled Tank, Exchanger Loose $42.18 Tool H LH Outboard First Fixture 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Tank, Exchanger $15.50 P.-P. Part H LH Outboard H LH Outboard Tank, Exchanger, H LH Outboard 3.0000 sec **3.0000 sec**

- $0.04 1 Tank, Exchanger Stamped Tank, Exchanger, Stamped $15.50 Tool H LH Outboard Stamping Press 0-60 Ton 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Tank, Exchanger, Stamped $15.50 Part H LH Outboard H LH Outboard Tank, Exchanger, H LH Outboard 0.0000 sec **0.7000 sec** $0.16 $0.00 1 Tank, Exchanger, Material Tank, Exchanger, Stamped Material

- - - Blank weight 0.069 lbs

- - **-** - - -

- - - Press Size 60 Ton Prog

- - **-** - - -

- - - Part Size after stamping (205 L

- - **-** - - - by 22 W by 12 H)mm

- - - Space for Printing

- - **-** - - - 

# Space for Printing

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $15.50 P.-P. Part H LH Outboard H Tank Endcap, Exchanger H Tank Endcap, 8.0000 sec **8.0000 sec**

- $0.09 2 Tank, Exchanger Exchanger $15.50 Tool H Tank Endcap, Stamping Press 0-60 Ton 0.0000 sec **0.0000 sec** $0.00 $0.00 2 Exchanger $15.50 Part H Tank Endcap, H Tank Endcap, Exchanger, H Tank Endcap, 0.0000 sec **0.6000 sec** $0.03 $0.00 2 Exchanger Material Exchanger, Material

- - - Blank weight 0.011 lbs

- - **-** - - -

- - - Press Size 25 Ton Prog

- - **-** - - -

- - - Part Size after stamping (24 L by

- - **-** - - - 21 W by 3 H)mm $42.18 Fastening H LH Outboard Insert Tab in Slot 2.0000 sec **2.0000 sec** $0.00 $0.02 2 Tank, Exchanger

- - - Space for Printing

- - **-** - - - 

# Design Profit ®

Page 31 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)**

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $42.91 P.-P. Part H LH Outboard H Inboard Tank, Exchanger, H Inboard Tank, 8.0000 sec **8.0000 sec**

- $0.09 1 Tank, Exchanger Stamping Exchanger, Stamping $42.91 Tool H Inboard Tank, Stamping Press 200-400 Ton 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger, Stamping $42.91 Part H Inboard Tank, H Inboard Tank, Exchanger, H Inboard Tank, 0.0000 sec **1.8000 sec** $0.16 $0.02 1 Exchanger, Material Exchanger, Stamping Material

- - - Blank weight 0.069 lbs

- - **-** - - -

- - - Press Size 300 Ton Prog

- - **-** - - -

- - - Part Size after stamping (205 L

- - **-** - - - by 24 W by 16 H)mm $42.18 Tool H LH Outboard Hand Tool 3.0000 sec **3.0000 sec** $0.00 $0.04 1 Tank, Exchanger $42.18 Fastening H LH Outboard Peen In Place 2.0000 sec **2.0000 sec** $0.00 $0.02 2 Tank, Exchanger $42.18 Operation H LH Outboard Part Manipulation 3.0000 sec **3.0000 sec** $0.00 $0.04 1 Tank, Exchanger 

# $42.18 Fastening H LH Outboard Peen In Place 2.0000 sec **2.0000 sec** $0.00 $0.02 2 Tank, Exchanger

- - - Space for Printing

- - **-** - - - $54.35 P.-P. Part H LH Outboard H Return Tube, Exchanger Asm H Return Tube, 5.0000 sec **5.0000 sec**

- $0.06 1 Tank, Exchanger Exchanger Asm $54.35 Tool H Return Tube, Tube Cutter 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm

- - - Start with Tube Stock

- - **-** - - - $54.35 P.-P. Part H Return Tube, H Return Tube, Exchanger, H Return Tube, 0.0000 sec **0.0000 sec** $0.08 $0.00 1 Exchanger Asm Material Exchanger, Material

- - - We ight before machining 0.0361

- - **-** - - - lbs $54.35 Operation H Return Tube, Clamp Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm $54.35 Material Mod. H Return Tube, Cut to Length 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Exchanger Asm $54.35 Operation H Return Tube, Unclamp Part 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Exchanger Asm 

# Design Profit ®

# Page 32 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $54.35 Tool H Return Tube, Tube Bending Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger Asm $54.35 Operation H Return Tube, Clamp Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm $54.35 Material Mod. H Return Tube, Crimp Tube 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Exchanger Asm $54.35 Operation H Return Tube, Unclamp Part 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Exchanger Asm $54.35 Operation H Return Tube, Clamp Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm $54.35 Material Mod. H Return Tube, Bend Tube 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Exchanger Asm $54.35 Operation H Return Tube, Unclamp Part 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Exchanger Asm $54.35 Operation H Return Tube, Part Manipulation 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm $54.35 Operation H Return Tube, Clamp Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm $54.35 Material Mod. H Return Tube, Crimp Tube 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Exchanger Asm $54.35 Operation H Return Tube, Unclamp Part 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Exchanger Asm 

# $54.35 Operation H Return Tube, CDI 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Exchanger Asm $54.35 Operation H Return Tube, Clamp Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger Asm $54.35 Material Mod. H Return Tube, Flare Tube End 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Exchanger Asm $54.35 Operation H Return Tube, Auto Tool Change 5.0000 sec **5.0000 sec** $0.00 $0.08 1 Exchanger Asm $54.35 Material Mod. H Return Tube, Flare Tube End - Double 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger Asm $54.35 Operation H Return Tube, Unclamp Part 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Exchanger Asm $42.18 Fastening H LH Outboard Push Tube in place 3.0000 sec **3.0000 sec** $0.00 $0.04 1 Tank, Exchanger

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - 

# Design Profit ®

# Page 33 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)**

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - 

# Space for Printing

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - 

# Design Profit ®

Page 34 of # Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)**

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $37.60 P.-P. Part H Exchanger H LH Mounting Bracket, H LH Mounting 5.0000 sec **5.0000 sec**

- $0.06 1 Asm, Assembled Exchanger, Deburred Bracket, Loose Exchanger, Deburred $37.60 Tool H LH Mounting Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Bracket, Exchanger, Deburred $31.33 P.-P. Part H LH Mounting H LH Mounting Bracket, H LH Mounting 3.0000 sec **3.0000 sec**

- $0.03 1 Bracket, Exchanger, Machined Bracket, Exchanger, Exchanger, Deburred Machined $31.33 Tool H LH Mounting EC-300-ML Horizontal CNC 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Bracket, Machine Exchanger, Machined $17.08 P.-P. Part H LH Mounting H LH Mounting Bracket, H LH Mounting 3.0000 sec **3.0000 sec**

- $0.03 1 Bracket, Exchanger, Extruded Bracket, Exchanger, Exchanger, 

# Machined Extruded $17.08 Tool H LH Mounting Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Bracket, Exchanger, Extruded $17.08 Part H LH Mounting H LH Mounting Bracket, H LH Mounting 0.0000 sec **0.0000 sec** $0.13 $0.00 1 Bracket, Exchanger, Material Bracket, Exchanger, Exchanger, Extruded Material $17.08 Material Mod. H LH Mounting Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Bracket, Exchanger, Extruded $31.33 Operation H LH Mounting Load Part 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Bracket, Exchanger, Machined $31.33 Operation H LH Mounting Clamp Part 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Bracket, Exchanger, Machined 

# Design Profit ®

# Page 35 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)**

- - - Bore hole

- - **-** - - - $31.33 Material Mod. H LH Mounting Bore Hole 1-30mm 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Bracket, Exchanger, Machined $31.33 Operation H LH Mounting Unclamp Part 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Bracket, Exchanger, Machined $31.33 Operation H LH Mounting Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.02 1 Bracket, Exchanger, Machined $37.60 Operation H LH Mounting Load Part 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Bracket, Exchanger, Deburred $37.60 Material Mod. H LH Mounting Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Bracket, Exchanger, Deburred $37.60 Operation H LH Mounting Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.02 1 Bracket, 

# Exchanger, Deburred

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $54.35 P.-P. Part H Exchanger H Locator Bracket, Exchanger, H Locator Bracket, 5.0000 sec **5.0000 sec**

- $0.06 1 Asm, Assembled Deburred Exchanger, Loose Deburred $54.35 Tool H Locator Bracket, Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger, Deburred



# Design Profit ®

# Page 36 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $17.08 P.-P. Part H Locator Bracket, H Locator Bracket, Exchanger, H Locator Bracket, 3.0000 sec **3.0000 sec**

- $0.05 1 Exchanger, Extruded Exchanger, Deburred Extruded $17.08 Tool H Locator Bracket, Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger, Extruded $17.08 Part H Locator Bracket, H Locator Bracket, Exchanger, H Locator Bracket, 0.0000 sec **0.0000 sec** $0.13 $0.00 1 Exchanger, Material Exchanger, Extruded Material $17.08 Material Mod. H Locator Bracket, Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Exchanger, Extruded $54.35 Operation H Locator Bracket, Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger, Deburred $54.35 Material Mod. H Locator Bracket, Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger, Deburred $54.35 Operation H Locator Bracket, Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger, Deburred $42.18 Operation H Exchanger Clamp Part 3.0000 sec **3.0000 sec** $0.00 $0.04 2



# Operation H Exchanger Clamp Part 3.0000 sec **3.0000 sec**

Asm, Assembled Loose $42.18 Operation H Exchanger 18" Move 2.0000 sec **2.0000 sec** $0.00 $0.02 1 Asm, Assembled Loose $42.18 Operation H Exchanger CDI 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Asm, Assembled Loose

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $42.18 Subassembly H Exchanger H RH Outboard Tank, Exchanger H RH Outboard 8.0000 sec **8.0000 sec**

- $0.09 1 Asm, Assembled Tank, Exchanger Loose $42.18 Tool H RH Outboard First Fixture 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Tank, Exchanger $42.91 P.-P. Part H RH Outboard H Inboard Tank, Exchanger, H Inboard Tank, 3.0000 sec **3.0000 sec**

- $0.04 1 Tank, Exchanger Stamping Exchanger, Stamping



# Design Profit ®

# Page 37 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $42.91 Tool H Inboard Tank, Stamping Press 200-400 Ton 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger, Stamping $42.91 Part H Inboard Tank, H Inboard Tank, Exchanger, H Inboard Tank, 0.0000 sec **1.8000 sec** $0.16 $0.02 1 Exchanger, Material Exchanger, Stamping Material

- - - Blank weight 0.069 lbs

- - **-** - - -

- - - Press Size 300 Ton Prog

- - **-** - - -

- - - Part Size after stamping (205 L

- - **-** - - - by 24 W by 16 H)mm

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $15.50 P.-P. Part H RH Outboard H Tank Endcap, Exchanger H Tank Endcap, 8.0000 sec **8.0000 sec**

- $0.09 2 Tank, Exchanger Exchanger $15.50 Tool H Tank Endcap, Stamping Press 0-60 Ton 0.0000 sec **0.0000 sec** $0.00 $0.00 2 Exchanger $15.50 Part H Tank Endcap, H Tank Endcap, Exchanger, H Tank Endcap, 0.0000 sec **0.6000 sec** $0.03 $0.00 2 Exchanger Material Exchanger, 

# Material

- - - Blank weight 0.011 lbs

- - **-** - - -

- - - Press Size 25 Ton Prog

- - **-** - - -

- - - Part Size after stamping (24 L by

- - **-** - - - 21 W by 3 H)mm $42.18 Fastening H RH Outboard Insert Tab in Slot 2.0000 sec **2.0000 sec** $0.00 $0.02 2 Tank, Exchanger

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $15.50 P.-P. Part H RH Outboard H RH Outboard Tank, Exchanger, H RH Outboard 8.0000 sec **8.0000 sec**

- $0.09 1 Tank, Exchanger Stamped Tank, Exchanger, Stamped $15.50 Tool H RH Outboard Stamping Press 0-60 Ton 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Tank, Exchanger, Stamped



# Design Profit ®

# Page 38 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $15.50 Part H RH Outboard H RH Outboard Tank, Exchanger, H RH Outboard 0.0000 sec **0.7000 sec** $0.16 $0.00 1 Tank, Exchanger, Material Tank, Exchanger, Stamped Material

- - - Blank weight 0.069 lbs

- - **-** - - -

- - - Press Size 60 Ton Prog

- - **-** - - -

- - - Part Size after stamping (205 L

- - **-** - - - by 22 W by 12 H)mm $42.18 Tool H RH Outboard Hand Tool 3.0000 sec **3.0000 sec** $0.00 $0.04 1 Tank, Exchanger $42.18 Fastening H RH Outboard Peen In Place 2.0000 sec **2.0000 sec** $0.00 $0.02 2 Tank, Exchanger $42.18 Operation H RH Outboard Part Manipulation 3.0000 sec **3.0000 sec** $0.00 $0.04 1 Tank, Exchanger $42.18 Fastening H RH Outboard Peen In Place 2.0000 sec **2.0000 sec** $0.00 $0.02 2 Tank, Exchanger

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - 

# Space for Printing

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $37.60 P.-P. Part H Exchanger H Fluid Pipe Fitting Exchanger H Fluid Pipe 5.0000 sec **5.0000 sec**

- $0.06 1 Asm, Assembled Asm, Ex truded Fitting Exchanger Loose Asm, Ex truded



# Design Profit ®

Page 39 of # Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $37.60 Tool H Fluid Pipe Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Fitting Exchanger Asm, Ex truded $31.33 P.-P. Part H Fluid Pipe H Fluid Pipe Fitting Exchanger H Fluid Pipe 3.0000 sec **3.0000 sec**

- $0.03 1 Fitting Exchanger Asm, Machined Fitting Exchanger Asm, Ex truded Asm, Machined $31.33 Tool H Fluid Pipe EC-300-ML Horizontal CNC 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Fitting Exchanger Machine Asm, Machined $17.08 P.-P. Part H Fluid Pipe H Fluid Pipe Fitting Exchanger H Fluid Pipe 3.0000 sec **3.0000 sec**

- $0.03 1 Fitting Exchanger Asm, Ex truded Fitting Exchanger Asm, Machined Asm, Machined-1 $17.08 Tool H Fluid Pipe Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Fitting Exchanger Asm, Ex truded $17.08 Part H Fluid Pipe H Fluid Pipe Fitting Exchanger H Fluid Pipe 0.0000 sec **0.0000 sec** $0.30 $0.00 1 Fitting Exchanger Asm, Material Fitting Exchanger Asm, Ex truded Asm, Material $17.08 Material Mod. H Fluid Pipe Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Fitting Exchanger Asm, Ex truded $31.33 Operation H Fluid Pipe Load Part 3.0000 sec **3.0000 sec** $0.00 $0.03 1



# Operation H Fluid Pipe Load Part 3.0000 sec **3.0000 sec**

Fitting Exchanger Asm, Machined $31.33 Operation H Fluid Pipe Clamp Part 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Fitting Exchanger Asm, Machined

- - - Mill face

- - **-** - - - $31.33 Material Mod. H Fluid Pipe Milled face 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Fitting Exchanger Asm, Machined $31.33 Operation H Fluid Pipe Auto Tool Change 5.0000 sec **5.0000 sec** $0.00 $0.04 1 Fitting Exchanger Asm, Machined

- - - Bore and tap hole

- - **-** - - - $31.33 Material Mod. H Fluid Pipe Drill and Tap Hole 1-30mm 5.0000 sec **5.0000 sec** $0.00 $0.04 1 Fitting Exchanger Asm, Machined $31.33 Operation H Fluid Pipe Auto Tool Change 5.0000 sec **5.0000 sec** $0.00 $0.04 1 Fitting Exchanger Asm, Machined

- - - Bore inner hole

- - **-** - - - 

# Design Profit ®

# Page 40 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $31.33 Material Mod. H Fluid Pipe Drill Hole 1-30mm 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Fitting Exchanger Asm, Machined $31.33 Operation H Fluid Pipe Auto Tool Change 5.0000 sec **5.0000 sec** $0.00 $0.04 1 Fitting Exchanger Asm, Machined

- - - Bore and chamfer outer hole

- - **-** - - - $31.33 Material Mod. H Fluid Pipe Drill & Chamfer Hole 1-30mm 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Fitting Exchanger Asm, Machined $31.33 Operation H Fluid Pipe Unclamp Part 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Fitting Exchanger Asm, Machined $31.33 Operation H Fluid Pipe Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.02 1 Fitting Exchanger Asm, Machined $37.60 Operation H Fluid Pipe Load Part 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Fitting Exchanger Asm, Ex truded $37.60 Material Mod. H Fluid Pipe Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Fitting Exchanger Asm, Ex truded 

# $37.60 Operation H Fluid Pipe Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.02 1 Fitting Exchanger Asm, Ex truded

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - 

# Design Profit ®

Page 41 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)**

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $37.60 P.-P. Part H Exchanger H RH Mounting Bracket, H RH Mounting 5.0000 sec **5.0000 sec**

- $0.06 1 Asm, Assembled Exchanger, Deburred Bracket, Loose Exchanger, Deburred $37.60 Tool H RH Mounting Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Bracket, Exchanger, Deburred $31.33 P.-P. Part H RH Mounting H RH Mounting Bracket, H RH Mounting 3.0000 sec **3.0000 sec**

- $0.03 1 Bracket, Exchanger, Machined Bracket, Exchanger, Exchanger, Deburred Machined $31.33 Tool H RH Mounting EC-300-ML Horizontal CNC 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Bracket, Machine Exchanger, Machined $17.08 P.-P. Part H RH Mounting H RH Mounting Bracket, H RH Mounting 3.0000 sec **3.0000 sec**

- $0.03 1 Bracket, Exchanger, Extruded Bracket, Exchanger, Exchanger, Machined Extruded 

# $17.08 Tool H RH Mounting Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Bracket, Exchanger, Extruded $17.08 Part H RH Mounting H RH Mounting Bracket, H RH Mounting 0.0000 sec **0.0000 sec** $0.13 $0.00 1 Bracket, Exchanger, Material Bracket, Exchanger, Exchanger, Extruded Material $17.08 Material Mod. H RH Mounting Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Bracket, Exchanger, Extruded $31.33 Operation H RH Mounting Load Part 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Bracket, Exchanger, Machined $31.33 Operation H RH Mounting Clamp Part 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Bracket, Exchanger, Machined

- - - Bore hole

- - **-** - - - 

# Design Profit ®

# Page 42 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $31.33 Material Mod. H RH Mounting Drill Hole 1-30mm 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Bracket, Exchanger, Machined $31.33 Operation H RH Mounting Unclamp Part 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Bracket, Exchanger, Machined $31.33 Operation H RH Mounting Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.02 1 Bracket, Exchanger, Machined $37.60 Operation H RH Mounting Load Part 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Bracket, Exchanger, Deburred $37.60 Material Mod. H RH Mounting Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Bracket, Exchanger, Deburred $37.60 Operation H RH Mounting Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.02 1 Bracket, Exchanger, 

# Deburred

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $54.35 P.-P. Part H Exchanger H Locator Bracket, Exchanger, H Locator Bracket, 5.0000 sec **5.0000 sec**

- $0.06 1 Asm, Assembled Deburred Exchanger, Loose Deburred $54.35 Tool H Locator Bracket, Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger, Deburred $17.08 P.-P. Part H Locator Bracket, H Locator Bracket, Exchanger, H Locator Bracket, 3.0000 sec **3.0000 sec**

- $0.05 1 Exchanger, Extruded Exchanger, Deburred Extruded


# Design Profit ®

# Page 43 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $17.08 Tool H Locator Bracket, Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Exchanger, Extruded $17.08 Part H Locator Bracket, H Locator Bracket, Exchanger, H Locator Bracket, 0.0000 sec **0.0000 sec** $0.13 $0.00 1 Exchanger, Material Exchanger, Extruded Material $17.08 Material Mod. H Locator Bracket, Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.02 1 Exchanger, Extruded $54.35 Operation H Locator Bracket, Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger, Deburred $54.35 Material Mod. H Locator Bracket, Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Exchanger, Deburred $54.35 Operation H Locator Bracket, Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Exchanger, Deburred $42.18 Operation H Exchanger Clamp Part 3.0000 sec **3.0000 sec** $0.00 $0.04 3 Asm, Assembled Loose $46.52 Operation H Exchanger Load Part 3.0000 sec **3.0000 sec** $0.00 $0.04 1



# Operation H Exchanger Load Part 3.0000 sec **3.0000 sec**

Asm, Trans Cooler, Brazed $46.52 Material Mod. H Exchanger Oven Braze large part 20.0000 sec **20.0000 sec** $0.00 $0.26 1 Asm, Trans Cooler, Brazed $46.52 Operation H Exchanger Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Asm, Trans Cooler, Brazed $49.29 Operation H Exchanger Load Part 3.0000 sec **3.0000 sec** $0.00 $0.04 1 Asm, Trans Cooler, W ashed $49.29 Operation H Exchanger Wa sh Part Medium 5.0000 sec **5.0000 sec** $0.00 $0.07 1 Asm, Trans Cooler, W ashed $49.29 Operation H Exchanger Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Asm, Trans Cooler, W ashed $55.17 Operation H Exchanger Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Asm, Trans Cooler, Painted


# Design Profit ®

# Page 44 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $55.17 Operation H Exchanger Paint Part Medium 5.0000 sec **5.0000 sec** $0.00 $0.08 1 Asm, Trans Cooler, Painted $55.17 Operation H Exchanger Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Asm, Trans Cooler, Painted $35.51 Part H Exchanger H Label, Exchanger Asm H Label, 10.0000 sec **10.0000 sec** $0.10 $0.10 1 Asm, Trans Exchanger Asm Cooler Asm $35.51 Fastening H Exchanger Apply Label 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Asm, Trans Cooler Asm

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -



# - - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - 

# Design Profit ®

Page 45 of # Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)**

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - 

# Space for Printing

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - 

# Design Profit ®

Page 46 of # Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)**

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - 

# Space for Printing

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $35.51 Subassembly H Cooler Asm, H Tube & Hose Asm, Trans H Tube & Hose 9.0000 sec **9.0000 sec**

- $0.09 1 Trans & DC-DC Cooler Asm Asm, Trans Mod Cooler Asm $35.51 Tool H Tube & Hose First Fixture 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Trans Cooler Asm $54.35 Subassembly H Tube & Hose H Tube Asm, Trans Cooler Asm H Tube Asm, 3.0000 sec **3.0000 sec**

- $0.03 1 Asm, Trans Trans Cooler Asm Cooler Asm 

# Design Profit ®

Page 47 of # Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $54.35 Tool H Tube Asm, Furnace/Oven 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Trans Cooler Asm $54.35 Subassembly H Tube Asm, H Tube Asm, Trans Cooler Asm, H Tube Asm, 3.0000 sec **3.0000 sec**

- $0.05 1 Trans Cooler Asm Pressed Trans Cooler Asm, Pressed $54.35 Tool H Tube Asm, Press 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Trans Cooler Asm, Pressed $44.85 P.-P. Part H Tube Asm, H Pipe, Tube Asm, Trans Cooler H Pipe, Tube 3.0000 sec **3.0000 sec**

- $0.05 1 Trans Cooler Asm, Trans Asm, Pressed Cooler $44.85 Tool H Pipe, Tube Tube Cutter 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Trans Cooler $44.85 Part H Pipe, Tube H Pipe, Tube Asm, Trans Cooler, H Pipe, Tube 0.0000 sec **0.0000 sec** $0.13 $0.00 1 Asm, Trans Material Asm, Trans Cooler Cooler, Material

- - - Start with Tube Stock

- - **-** - - -

- - - We ight before machining 0.1026

- - **-** - - - lbs $44.85 Operation H Pipe, Tube Clamp Part 3.0000 sec **3.0000 sec** $0.00 $0.04 1 Asm, Trans 

# Cooler $44.85 Material Mod. H Pipe, Tube Cut to Length 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Asm, Trans Cooler $44.85 Operation H Pipe, Tube Unclamp Part 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Asm, Trans Cooler $44.85 Tool H Pipe, Tube Tube Bending Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Trans Cooler $44.85 Operation H Pipe, Tube Clamp Part 3.0000 sec **3.0000 sec** $0.00 $0.04 1 Asm, Trans Cooler $44.85 Material Mod. H Pipe, Tube Bend Tube 1.0000 sec **1.0000 sec** $0.00 $0.01 2 Asm, Trans Cooler $44.85 Operation H Pipe, Tube CDI 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Asm, Trans Cooler


# Design Profit ®

# Page 48 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $44.85 Operation H Pipe, Tube Unclamp Part 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Asm, Trans Cooler $44.85 Operation H Pipe, Tube Part Manipulation 3.0000 sec **3.0000 sec** $0.00 $0.04 1 Asm, Trans Cooler $44.85 Operation H Pipe, Tube Clamp Part 3.0000 sec **3.0000 sec** $0.00 $0.04 1 Asm, Trans Cooler $44.85 Material Mod. H Pipe, Tube Crimp Tube 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Asm, Trans Cooler $44.85 Operation H Pipe, Tube Unclamp Part 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Asm, Trans Cooler $44.85 Operation H Pipe, Tube CDI 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Asm, Trans Cooler $44.85 Operation H Pipe, Tube Clamp Part 3.0000 sec **3.0000 sec** $0.00 $0.04 1 Asm, Trans Cooler $44.85 Material Mod. H Pipe, Tube Flare Tube End 1.0000 sec **1.0000 sec** $0.00 $0.01 1



# Material Mod. H Pipe, Tube Flare Tube End 1.0000 sec **1.0000 sec**

Asm, Trans Cooler $44.85 Operation H Pipe, Tube Auto Tool Change 5.0000 sec **5.0000 sec** $0.00 $0.06 1 Asm, Trans Cooler $44.85 Material Mod. H Pipe, Tube Flare Tube End - Double 2.0000 sec **2.0000 sec** $0.00 $0.02 1 Asm, Trans Cooler $44.85 Operation H Pipe, Tube Unclamp Part 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Asm, Trans Cooler

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - 

# Design Profit ®

Page 49 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)**

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $10.75 P.-P. Part H Tube Asm, H Fitting, Tube Asm, W ashed H Fitting, Tube 5.0000 sec **5.0000 sec**

- $0.08 1 Trans Cooler Asm, W ashed Asm, Pressed $10.75 Tool H Fitting, Tube Wa sher Duo 400 W ash Rinse & 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, W ashed DRY 

# $37.60 P.-P. Part H Fitting, Tube H Fitting, Tube Asm, Deburred H Fitting, Tube 3.0000 sec **3.0000 sec**

- $0.01 1 Asm, W ashed Asm, Deburred $37.60 Tool H Fitting, Tube Deburing Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Deburred $31.33 P.-P. Part H Fitting, Tube H Fitting, Tube Asm, Machined H Fitting, Tube 3.0000 sec **3.0000 sec**

- $0.03 1 Asm, Deburred Asm, Machined $31.33 Tool H Fitting, Tube EC-300-ML Horizontal CNC 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Machined Machine $54.35 P.-P. Part H Fitting, Tube H Fitting, Tube Asm, Extruded H Fitting, Tube 3.0000 sec **3.0000 sec**

- $0.03 1 Asm, Machined Asm, Ex truded $54.35 Tool H Fitting, Tube Extrusion Equipment 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Ex truded $54.35 Part H Fitting, Tube H Fitting, Tube Asm, Material H Fitting, Tube 0.0000 sec **2.4500 sec** $0.57 $0.04 1 Asm, Ex truded Asm, Material

- - - Assumed a 0.0594 lb Extrusion

- - **-** - - - Before Machining $54.35 Tool H Fitting, Tube Cut Off Tool 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Asm, Ex truded 

# Design Profit ®

Page 50 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $54.35 Material Mod. H Fitting, Tube Cut to Length 4.0000 sec **4.0000 sec** $0.00 $0.06 1 Asm, Ex truded $31.33 Operation H Fitting, Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Asm, Machined $31.33 Operation H Fitting, Tube Clamp Part 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Asm, Machined

- - - Machine Rear Face & Chamfer

- - **-** - - - Bolt Hole $31.33 Material Mod. H Fitting, Tube Mill Flat Med 4.0000 sec **4.0000 sec** $0.00 $0.03 1 Asm, Machined $31.33 Operation H Fitting, Tube Auto Tool Change 5.0000 sec **5.0000 sec** $0.00 $0.04 1 Asm, Machined $31.33 Material Mod. H Fitting, Tube Chamfer ID 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Asm, Machined

- - - Machine Tube Bore

- - **-** - - - $31.33 Operation H Fitting, Tube Auto Tool Change 5.0000 sec **5.0000 sec** $0.00 $0.04 1 Asm, Machined $31.33 Material Mod. H Fitting, Tube Drill Hole 1-30mm 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Asm, Machined $31.33 Operation H Fitting, Tube CDI 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Asm, Machined

- - - Machine Fitting Bore & Chamfer

- - **-** - - - 

# Machine Fitting Bore & Chamfer $31.33 Material Mod. H Fitting, Tube Drill Hole 1-30mm 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Asm, Machined $31.33 Operation H Fitting, Tube Auto Tool Change 5.0000 sec **5.0000 sec** $0.00 $0.04 1 Asm, Machined $31.33 Material Mod. H Fitting, Tube Chamfer ID 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Asm, Machined

- - - Turn Face, Fitting & O-ring Land

- - **-** - - - $31.33 Operation H Fitting, Tube Auto Tool Change 5.0000 sec **5.0000 sec** $0.00 $0.04 1 Asm, Machined $31.33 Material Mod. H Fitting, Tube Mill Flat Med 4.0000 sec **4.0000 sec** $0.00 $0.03 1 Asm, Machined $31.33 Operation H Fitting, Tube Reposition Cutting Tool 2.0000 sec **2.0000 sec** $0.00 $0.02 1 Asm, Machined $31.33 Material Mod. H Fitting, Tube Turn OD 1-30mm 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Asm, Machined $31.33 Operation H Fitting, Tube Reposition Cutting Tool 2.0000 sec **2.0000 sec** $0.00 $0.02 1 Asm, Machined $31.33 Material Mod. H Fitting, Tube Turn OD Contoured surface fins 5.0000 sec **5.0000 sec** $0.00 $0.04 1 Asm, Machined 

# Design Profit ®

# Page 51 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $31.33 Operation H Fitting, Tube Auto Tool Change 5.0000 sec **5.0000 sec** $0.00 $0.04 1 Asm, Machined $31.33 Material Mod. H Fitting, Tube Cut Groove sml 2.0000 sec **2.0000 sec** $0.00 $0.02 1 Asm, Machined

- - - Chamfer Bolt Bore

- - **-** - - - $31.33 Operation H Fitting, Tube Auto Tool Change 5.0000 sec **5.0000 sec** $0.00 $0.04 1 Asm, Machined $31.33 Material Mod. H Fitting, Tube Chamfer ID 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Asm, Machined $31.33 Operation H Fitting, Tube Unclamp Part 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Asm, Machined $31.33 Operation H Fitting, Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.02 1 Asm, Machined $37.60 Operation H Fitting, Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Asm, Deburred $37.60 Material Mod. H Fitting, Tube Debur/Tumble 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Asm, Deburred $37.60 Operation H Fitting, Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.02 1 Asm, Deburred $10.75 Operation H Fitting, Tube Load Part 3.0000 sec **3.0000 sec** $0.00 $0.01 1 Asm, W ashed $10.75 Operation H Fitting, Tube Wa sh Part Medium 5.0000 sec **5.0000 sec** $0.00 $0.01 1



# Operation H Fitting, Tube sh Part Medium 5.0000 sec **5.0000 sec**

Asm, W ashed $10.75 Operation H Fitting, Tube Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.01 1 Asm, W ashed $54.35 Fastening H Tube Asm, Press Together 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Trans Cooler Asm, Pressed $54.35 Operation H Tube Asm, Load Part 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Trans Cooler Asm $54.35 Material Mod. H Tube Asm, Oven Braze 5.0000 sec **5.0000 sec** $0.00 $0.08 1 Trans Cooler Asm $54.35 Operation H Tube Asm, Unload Part 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Trans Cooler Asm $35.51 Part H Tube & Hose H O-Ring, 18.5 x 2.5 mm H O-Ring, 18.5 x 7.0000 sec **7.0000 sec** $0.06 $0.07 1 Asm, Trans 2.5 mm Cooler Asm $35.51 Fastening H Tube & Hose Push Seal in Place 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Asm, Trans Cooler Asm


# Design Profit ®

Page 52 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $35.51 Operation H Tube & Hose CDI 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Asm, Trans Cooler Asm

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - 

# Space for Printing

- - - Space for Printing

- - **-** - - -

- - - Space for Printing

- - **-** - - - $35.94 P.-P. Part H Tube & Hose H Rubber Tube, 17 mm Diam H Rubber Tube, 7.0000 sec **7.0000 sec**

- $0.07 1 Asm, Trans 17 mm Diam Cooler Asm $35.94 Tool H Rubber Tube, Extruder 32mm Base 0.0000 sec **0.0000 sec** $0.00 $0.00 1 17 mm Diam $35.94 Part H Rubber Tube, H Rubber Tube, 17 mm Diam, H Rubber Tube, 0.0000 sec **0.6432 sec** $0.01 $0.01 1 17 mm Diam Material 17 mm Diam, Material

- - - Box Size 27mmL x 22mmW x - - **-** - - - 22mmH $35.51 Fastening H Tube & Hose Push Tube in place 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Asm, Trans Cooler Asm $35.51 Part H Tube & Hose H Heat Shrink Fabric Tube, 21 H Heat Shrink 9.0000 sec **9.0000 sec** $0.07 $0.09 1 Asm, Trans mm Diam Fabric Tube, 21 Cooler Asm mm Diam 

# Design Profit ®

Page 53 of #

# Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $35.51 Fastening H Tube & Hose Position Part 1.0000 sec **1.0000 sec** $0.00 $0.01 1 Asm, Trans Cooler Asm $35.51 Tool H Tube & Hose Heat Gun 2.0000 sec **2.0000 sec** $0.00 $0.02 1 Asm, Trans Cooler Asm $35.51 Fastening H Tube & Hose Apply Heat Locally 5.0000 sec **5.0000 sec** $0.00 $0.05 1 Asm, Trans Cooler Asm $54.35 Subassembly H Tube & Hose H Hose Asm, Trans Cooler H Hose Asm, 9.0000 sec **9.0000 sec**

- $0.09 1 Asm, Trans Trans Cooler Cooler Asm $54.35 Tool H Hose Asm, First Fixture 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Trans Cooler $35.94 P.-P. Part H Hose Asm, H Hose Asm, Trans Cooler H Hose, Trans 4.0000 sec **4.0000 sec**

- $0.06 1 Trans Cooler Cooler $35.94 Tool H Hose Asm, Extruder 32mm Base 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Trans Cooler $35.94 Part H Hose Asm, H Hose, Trans Cooler, Material H Hose, Trans 0.0000 sec **5.0373 sec** $0.25 $0.05 1 Trans Cooler Cooler, Material

- - - Box Size 190mmL x 98mmW x - - **-** - - - 35mmH 

# $54.35 Part H Hose Asm, H Oetiker Clamp, Medium H Oetiker Clamp, 7.0000 sec **7.0000 sec** $0.00 $0.11 1 Trans Cooler (26.5mm) Medium (26.5mm) $54.35 Fastening H Hose Asm, Slide into Position 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Trans Cooler $54.35 Operation H Hose Asm, CDI 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Trans Cooler $54.35 Part H Hose Asm, H Hose Clamp, Medium (27mm) H Hose Clamp, 7.0000 sec **7.0000 sec** $0.23 $0.11 1 Trans Cooler Medium (27mm) $54.35 Tool H Hose Asm, Hand Tool 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Trans Cooler $54.35 Fastening H Hose Asm, Relase Hose Spring Clamp 2.0000 sec **2.0000 sec** $0.00 $0.03 1 Trans Cooler $35.51 Operation H Tube & Hose Press part 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Asm, Trans Cooler Asm $35.51 Tool H Tube & Hose Hand Tool 3.0000 sec **3.0000 sec** $0.00 $0.03 1 Asm, Trans Cooler Asm



# Design Profit ®

# Page 54 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $35.51 Fastening H Tube & Hose Crimp Oetiker Clamp 2.0000 sec **2.0000 sec** $0.00 $0.02 1 Asm, Trans Cooler Asm $35.51 Part H Cooler Asm, H Bolt, Line Asm to Exchanger H Bolt, Line Asm 4.0000 sec **4.0000 sec** $0.06 $0.04 1 Trans & DC-DC to Exchanger Mod $35.51 Tool H Cooler Asm, Power Tool 4.0000 sec **4.0000 sec** $0.00 $0.04 1 Trans & DC-DC Mod $35.51 Fastening H Cooler Asm, Power Screw 4.0000 sec **4.0000 sec** $0.00 $0.04 1 Trans & DC-DC Mod $83.31 Fastening H Trans & DC-DC Slide into Position 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Cooling System $83.31 Part H Trans & DC-DC H Bolt, Trans Cooler to FEM H Bolt, Trans 4.0000 sec **4.0000 sec** $0.06 $0.09 1 Cooling System Cooler to FEM $83.31 Tool H Trans & DC-DC Power Tool 4.0000 sec **4.0000 sec** $0.00 $0.09 1 Cooling System $83.31 Fastening H Trans & DC-DC Power Screw 4.0000 sec **4.0000 sec** $0.00 $0.09 1 Cooling System $83.31 Operation H Trans & DC-DC 18" Move 2.0000 sec **2.0000 sec** $0.00 $0.05 1 Cooling System 

# $83.31 Fastening H Trans & DC-DC Slide into Position 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Cooling System $83.31 Part H Trans & DC-DC H Bolt, Trans Cooler to FEM H Bolt, Trans 4.0000 sec **4.0000 sec** $0.06 $0.09 1 Cooling System Cooler to FEM $83.31 Tool H Trans & DC-DC Power Tool 4.0000 sec **4.0000 sec** $0.00 $0.09 1 Cooling System $83.31 Fastening H Trans & DC-DC Power Screw 4.0000 sec **4.0000 sec** $0.00 $0.09 1 Cooling System $83.31 Operation H Trans & DC-DC CDI 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Cooling System

- - - Install FEM/Cooler Hose to

- - **-** - - - DC-DC Module $83.31 Multitouch H Trans & DC-DC H Regrab Hose, FEM to DC-DC H Regrab Hose, 8.0000 sec **8.0000 sec** $0.00 $0.19 1 Cooling System Module FEM to DC-DC Module $83.31 Fastening H Trans & DC-DC Press Together 3.0000 sec **3.0000 sec** $0.00 $0.07 1 Cooling System $83.31 Tool H Trans & DC-DC Hand Tool 3.0000 sec **3.0000 sec** $0.00 $0.07 1 Cooling System


# Design Profit ®

# Page 55 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $83.31 Fastening H Trans & DC-DC Relase Hose Spring Clamp 2.0000 sec **2.0000 sec** $0.00 $0.05 1 Cooling System

- - - Install Hose, Cooler to Trans

- - **-** - - - $54.35 Subassembly H Trans & DC-DC H Trans Cooler Line Asm, E H Trans Cooler 8.0000 sec **8.0000 sec**

- $0.19 1 Cooling System Motor Cooling Line Asm, E Motor Cooling $54.35 Tool H Trans Cooler First Fixture 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Line Asm, E Motor Cooling $35.94 P.-P. Part H Trans Cooler H Trans Cooler Line, E Motor H Trans Cooler 4.0000 sec **4.0000 sec**

- $0.06 1 Line Asm, E Motor Cooling Line, E Motor Cooling Cooling $35.94 Tool H Trans Cooler Extruder 32mm Base 0.0000 sec **0.0000 sec** $0.00 $0.00 1 Line, E Motor Cooling $35.94 Part H Trans Cooler H Trans Cooler Line, E Motor H Trans Cooler 0.0000 sec **12.2948 sec** $0.59 $0.12 1 Line, E Motor Cooling, Material Line, E Motor Cooling Cooling, Material

- - - Box Size 410mmL x 165mmW x - - **-** - - - 93mmH $54.35 Part H Trans Cooler H Hose Clamp, Medium (24mm) H Hose Clamp, 7.0000 sec **7.0000 sec** $0.22 $0.11 1 Line Asm, E Motor Medium (24mm) 

# Cooling $54.35 Part H Trans Cooler H Hose Clamp, Medium (27mm) H Hose Clamp, 7.0000 sec **7.0000 sec** $0.23 $0.11 1 Line Asm, E Motor Medium (27mm) Cooling $54.35 Tool H Trans Cooler Hand Tool 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Line Asm, E Motor Cooling $54.35 Fastening H Trans Cooler Relase Hose Spring Clamp 2.0000 sec **2.0000 sec** $0.00 $0.03 2 Line Asm, E Motor Cooling $54.35 Operation H Trans Cooler CDI 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Line Asm, E Motor Cooling $54.35 Part H Trans Cooler H Strap On Christmas Tree Clip H Strap On 10.0000 sec **10.0000 sec** $0.04 $0.15 1 Line Asm, E Motor (#30) Christmas Tree Cooling Clip (#30) $54.35 Fastening H Trans Cooler Zip Tie 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Line Asm, E Motor Cooling


# Design Profit ®

# Page 56 of #

Copyright 2010 © Design Profit, Inc.

# H Trans & DC-DC Cooling Sy **stem**

**Labor Ty**  **pe Parent Name**  **Sy mbol Name**  **Number Munro Score**  **Actual Time Piece Cost**  **Total Labor Qty** 

**Rate Cost**  **(Total)** $54.35 Tool H Trans Cooler Hand Tool 3.0000 sec **3.0000 sec** $0.00 $0.05 1 Line Asm, E Motor Cooling $54.35 Fastening H Trans Cooler Trim to Length 1.0000 sec **1.0000 sec** $0.00 $0.02 1 Line Asm, E Motor Cooling

- - - Mate Cooler Junction (Photo N/A)

- - **-** - - - $83.31 Fastening H Trans & DC-DC Press Together 3.0000 sec **3.0000 sec** $0.00 $0.07 1 Cooling System $83.31 Tool H Trans & DC-DC Hand Tool 3.0000 sec **3.0000 sec** $0.00 $0.07 1 Cooling System $83.31 Fastening H Trans & DC-DC Relase Hose Spring Clamp 2.0000 sec **2.0000 sec** $0.00 $0.05 1 Cooling System $83.31 Multitouch H Trans & DC-DC Regrab Cooler to Trans Hose Regrab Cooler to 8.0000 sec **8.0000 sec** $0.00 $0.19 1 Cooling System Trans Hose $83.31 Fastening H Trans & DC-DC Press in Xmass Clip 3.0000 sec **3.0000 sec** $0.00 $0.07 1 Cooling System

- - - Mate Cooler Hose to Trans

- - **-** - - - $83.31 Multitouch H Trans & DC-DC Regrab Cooler to Trans Hose Regrab Cooler to 8.0000 sec **8.0000 sec** $0.00 $0.19 1 Cooling System Trans Hose $83.31 Fastening H Trans & DC-DC Press Together 3.0000 sec **3.0000 sec** $0.00 $0.07 1 Cooling System 

# $83.31 Tool H Trans & DC-DC Hand Tool 3.0000 sec **3.0000 sec** $0.00 $0.07 1 Cooling System $83.31 Fastening H Trans & DC-DC Relase Hose Spring Clamp 2.0000 sec **2.0000 sec** $0.00 $0.05 1 Cooling System 

# Report Totals **Count:** ##

**681**



# Design Profit ®

Page 57 of #

# Copyright 2010 © Design Profit, Inc.

# Piece Co

**(Total)** $0.00

-

-

$0.00

-

$0.00

-

$0.00



# -

$0.00

-

$0.00

$0.40

-

-

-

# Piece Co

**(Total)**

-

$0.00

$0.18

-

-

-

$0.00

-

$0.00

$0.02



# $0.00

$0.00

$0.00

-

-

$0.00

-

$0.00

-

# Piece Co

**(Total)** $0.00

$0.03

-

-

-

$0.00

$0.00

$0.00

$0.00

$0.10

$0.00



# -

$0.00

-

$0.00

$0.15

-

# Piece Co

**(Total)** $0.18

$0.22

$0.21

$0.00

$0.00

$0.00

$0.00

$0.00



# $0.00

$0.06

$0.00

$0.00

$0.00

$0.06

$0.00

$0.00

# Piece Co

**(Total)** $0.00

$0.00

$0.00

$0.00

$0.00

-

-

$0.00

-

$0.00

$0.00

-



# $0.00

$0.05

-

-

-

$0.00

-

$0.00

# Piece Co

**(Total)** $0.08

-

-

-

$0.00

$0.00

$0.00

-

$0.00

-



# $0.00

-

-

$0.00

-

$0.00

$0.14

-

# Piece Co

**(Total)**

-

-

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00



# $0.01

$0.00

$0.00

-

$0.00

-

$0.00

# Piece Co

**(Total)** $0.37

-

$0.46

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00



# $0.00

-

$0.00

-

$0.00

$0.55

-

# Piece Co

**(Total)** $1.19

$0.46

$0.00

$0.00

$0.00

$0.04

$0.00

$0.00



# $0.00

-

$0.00

$0.05

-

-

-

# Piece Co

**(Total)** $0.00

$0.00

$0.00

$0.00

$0.12

$0.00

$0.00

$0.00

$0.00

-

$0.00



# $0.00

$0.00

$0.00

- $0.00

$0.00

$0.00

$0.00

$0.00

-

# Piece Co

**(Total)**

-

-

-

-

-

-

-

-

-

$0.00

-

$0.00

-



# $0.00

-

-

$0.00

-

$0.00

# Piece Co

**(Total)**

-

$0.00

-

$0.00

-

-

$0.00

-

$0.00



# $0.76

$0.00

$0.00

$0.00

$0.00

-

-

-

# Piece Co

**(Total)**

-

-

-

$0.00

$0.08

- $0.00

-

-

-

-

-

$0.00



# -

$0.00

$0.76

$0.00

$0.00

$0.00

# Piece Co

**(Total)** $0.00

-

-

-

-

-

-

$0.00

$0.08

- $0.00

-

-

-

-



# -

$0.00

-

$0.00

$0.76

$0.00

# Piece Co

**(Total)** $0.00

$0.00

$0.00

-

-

-

-

-

-

$0.00

$0.08

- $0.00



# -

-

-

-

-

$0.00

-

$0.00

# Piece Co

**(Total)** $0.76

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-



# $0.00

$0.08

- $0.00

-

-

-

-

-

$0.00

# Piece Co

**(Total)**

-

$0.00

$0.76

$0.00

$0.00

$0.00

$0.00

-



# -

-

-

-

-

$0.00

$0.08

- $0.00

-

-

-

-

# Piece Co

**(Total)**

-

$0.00

-

$0.00

$0.76

$0.00

$0.00

$0.00



# $0.00

-

-

-

-

-

-

$0.00

$0.08

- $0.00

# Piece Co

**(Total)**

-

-

-

-

-

$0.00

-

$0.00

$0.76

$0.00



# $0.00

$0.00

$0.00

-

-

-

-

-

-

$0.00

# Piece Co

**(Total)** $0.08

- $0.00

-

-

-

-

-

$0.00

-

$0.00

$0.76



# $0.00

$0.00

$0.00

$0.00

-

-

-

-

-

# Piece Co

**(Total)**

-

$0.00

$0.08

- $0.00

-

-

-

-

-

$0.00

-



# $0.00

$0.76

$0.00

$0.00

$0.00

$0.00

-

# Piece Co

**(Total)**

-

-

-

-

-

$0.00

$0.08

- $0.00

-

-

-

-

-

$0.00



# -

$0.00

$0.76

$0.00

$0.00

$0.00

# Piece Co

**(Total)** $0.00

-

-

-

-

-

-

$0.00

$0.08

- $0.00

-

-

-

-



# -

$0.00

-

$0.00

$0.76

$0.00

# Piece Co

**(Total)** $0.00

$0.00

$0.00

-

-

-

-

-

-

$0.00

$0.08

- $0.00



# -

-

-

-

-

$0.00

-

$0.00

# Piece Co

**(Total)** $0.76

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-



# $0.00

$0.08

- $0.00

-

-

-

-

-

$0.00

# Piece Co

**(Total)**

-

$0.00

$0.76

$0.00

$0.00

$0.00

$0.00

-



# -

-

-

-

-

$0.00

$0.08

- $0.00

-

-

-

-

# Piece Co

**(Total)**

-

$0.00

-

$0.00

$0.76

$0.00

$0.00

$0.00



# $0.00

-

-

-

-

-

-

$0.00

$0.08

- $0.00

# Piece Co

**(Total)**

-

-

-

-

-

$0.00

-

$0.00

$0.76

$0.00



# $0.00

$0.00

$0.00

-

-

-

-

-

-

$0.00

# Piece Co

**(Total)** $0.08

- $0.00

-

-

-

-

-

$0.00

-

$0.00

$0.76



# $0.00

$0.00

$0.00

$0.00

-

-

-

-

-

# Piece Co

**(Total)**

-

$0.00

$0.08

- $0.00

-

-

-

-

-

$0.00

-



# $0.00

$0.76

$0.00

$0.00

$0.00

$0.00

$0.00

# Piece Co

**(Total)** $0.00

-

$0.00

-

$0.00

$0.16

-

-

-

-



# -

-

-

-

-

$0.00

$0.05

-

-

-

$0.00

-

# Piece Co

**(Total)**

-

-

-

-

$0.00

$0.16

-

-

-

$0.00

$0.00

$0.00



# $0.00

-

-

$0.00

- $0.08

-

$0.00

$0.00

$0.00

# Piece Co

**(Total)** $0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00



# $0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

# Piece Co

**(Total)**

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-



# -

-

-

-

-

-

-

-

-

-

-

-

-

-

-

# Piece Co

**(Total)**

-

-

-

-

$0.00

-

$0.00

-



# $0.00

$0.13

$0.00

$0.00

$0.00

# Piece Co

**(Total)**

- $0.00

$0.00

$0.00

$0.00

$0.00

$0.00



# -

-

-

-

-

-

-

-

-

$0.00

# Piece Co

**(Total)**

-

$0.00

$0.13

$0.00

$0.00

$0.00

$0.00

$0.00



# $0.00

$0.00

-

-

-

$0.00

-

# Piece Co

**(Total)** $0.00

$0.16

-

-

-

-

-

-

-

-

-

$0.00

$0.05



# -

-

-

$0.00

-

-

-

-

-

$0.00

# Piece Co

**(Total)** $0.16

-

-

-

$0.00

$0.00

$0.00

$0.00

-

-

-

-

-

-



# -

-

-

-

-

-

-

-

-

-

-

-

-

# Piece Co

**(Total)** $0.00

-

$0.00

-

$0.00

$0.30

$0.00

$0.00



# $0.00

- $0.00

$0.00

- $0.00

$0.00

-

# Piece Co

**(Total)** $0.00

$0.00

- $0.00

$0.00

$0.00

$0.00

$0.00



# $0.00

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

# Piece Co

**(Total)**

-

-

-

$0.00

-

$0.00

-



# $0.00

$0.13

$0.00

$0.00

$0.00

-

# Piece Co

**(Total)** $0.00

$0.00

$0.00

$0.00

$0.00

$0.00



# -

-

-

-

-

-

-

-

-

$0.00

-

# Piece Co

**(Total)** $0.00

$0.13

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00



# $0.00

$0.00

$0.00

$0.00

$0.00

$0.00

# Piece Co

**(Total)** $0.00

$0.00

$0.10

$0.00

-

-

-

-

-

-

-

-

-



# -

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

# Piece Co

**(Total)**

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-



# -

-

-

-

-

-

-

-

-

-

-

-

-

-

-

# Piece Co

**(Total)**

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-



# -

-

-

-

-

-

-

-

-

$0.00

-

# Piece Co

**(Total)** $0.00

-

$0.00

-

$0.00

$0.13

-

-

$0.00



# $0.00

$0.00

$0.00

$0.00

$0.00

$0.00

# Piece Co

**(Total)** $0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00



# $0.00

$0.00

$0.00

-

-

-

-

-

-

-

-

# Piece Co

**(Total)**

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

$0.00



# -

$0.00

-

$0.00

-

$0.00

$0.57

-

$0.00

# Piece Co

**(Total)** $0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

- $0.00

$0.00

$0.00

- 

# $0.00

$0.00

$0.00

- $0.00

$0.00

$0.00

$0.00

$0.00

$0.00

# Piece Co

**(Total)** $0.00

$0.00

- $0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00

$0.00



# $0.00

$0.00

$0.00

$0.00

$0.00

$0.06

$0.00

# Piece Co

**(Total)** $0.00

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-



# -

-

-

$0.00

$0.01

-

$0.00

$0.07

# Piece Co

**(Total)** $0.00

$0.00

$0.00

-

$0.00

-

$0.00

$0.25

-



# $0.00

$0.00

$0.00

$0.23

$0.00

$0.00

$0.00

$0.00

# Piece Co

**(Total)** $0.00

$0.06

$0.00

$0.00

$0.00

$0.06

$0.00

$0.00

$0.00



# $0.00

$0.06

$0.00

$0.00

$0.00

-

$0.00

$0.00

$0.00

# Piece Co

**(Total)** $0.00

-

-

$0.00

-

$0.00

$0.59

-

$0.22



# $0.23

$0.00

$0.00

$0.00

$0.04

$0.00

# Piece Co

**(Total)** $0.00

$0.00

- $0.00

$0.00

$0.00

$0.00

$0.00

- $0.00

$0.00



# $0.00

$0.00

**$23.64**

### 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 **Ac cessory** 

**Drive Subsy stem** 

1 **00 Assembly of Accessory Drive Subsystem**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF!**

**- $** 

**-**

**$**

**-**

**$ #REF!**  **#REF! #REF!**  **#REF!**



### 2 **01 Pulleys** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 3 **02 Tensioners**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF!**

**- $** 

**-**

**$**

**-**

**$ 4.75** 

**$ 2.64** 

**$ 3.16** 

**$ 10.55** 

**$**



### 4 **03 Guides** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 5 **05 Belts**  **4.89 $**  **1.09**

**$ 4.89** 

**$ 10.86** 

**$ 0.05** 

**$ 0.71** 

**$ 0.65** 

**$ 0.27** 

**$ 1.68** 

**$ 0.02** 

**$ 12.56** 

**$**

**-**

**$**

**-**

**$**

**-**

**$ 2.85** 

**$ 0.63** 

**$ 2.85** 

**$ 6.33** 

**$** Markup **Net Component/**  **Assembly Cost Impact to**  **OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)**  Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**ItemSubsystem 

### System **ED&T/R&D (x1000)**  

### Sub-Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTION **NEW TECHNOLOGY GENERAL PART INFORMATION: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV**  **(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)**

Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly) Tooling**  **(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **Technology Level:**  Mild Hybrid, Start

- Stop Technology **Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

# Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

6 **65 Adaptors** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 7 **70 Pipes, Hoses, Ducting** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 8 **75 Brackets**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF!**

**- $** 

**-**

**$**

**-**

**$ #REF!**  **#REF! #REF!**  **#REF!**



### 9 **80 Boltings** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 10 **85 Sealing Elements** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 11 **90 Bearings Elements Misc** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 12 **95 Tools** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 13 **99 Miscellaneous** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0 **0 0** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0 **0 0** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0 **0 0** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0 **0 0** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0 **0 0** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0 **0 0** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0 **0 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

Markup **Net Component/**  **Assembly Cost Impact to**  **OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)**  Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**ItemSubsystem 

### System **ED&T/R&D (x1000)**  

### Sub-Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTION **NEW TECHNOLOGY GENERAL PART INFORMATION: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV**  **(Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)**

Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly) Tooling**  **(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **Technology Level:**  Mild Hybrid, Start

- Stop Technology **Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

# Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

**#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF!**

**- $** 

**-**

**$**

**-**

**$** 

### #REF! **#REF! #REF!**  **#REF! SUBSYSTEM 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 **Ac cessory** 

**Drive Subsy stem** 

1 **00**

2 **01**

3 **02**

4 **03**

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

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ #REF!** 

**- $** 

**-**

**$**

**-**

**$ #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!** 

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**0.05 $**  **0.69**

**$ 0.63** 

**$ 0.26** 

**$ 1.63** 

**$ 0.04** 

**$ 12.22** 

**$**

**-**

**$**

**-**

**$**

**-**

**$ #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!** 

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**0.03 $**  **0.41**

**$ 0.38** 

**$ 0.16** 

**$ 0.98** 

**$ 0.02** 

**$ 7.33** 

**$**

**-**

**$**

**-**

**$**

**-**

**$ 2.04** 

**$ 0.45** 

**$ 2.04** 

**$ 4.53** 

**$ 0.02** 

**$ 0.29** 

**$ 0.27** 

**$ 0.11** 

**$ 0.70** 

**$**

**-**

**$ 5.23** 

**$**

**-**

**$**

**-**

**$** 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)** 

# 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**  

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb**

6 **65**

7 **70**

8 **75**

9 **80**

10 **85**

11 **90**

12 **95**

13 **99**

0 **0**

0 **0**

0 **0**

0 **0**

0 **0**

0 **0 -** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF!**

**- $** 

**-**

**$**

**-**

**$ #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!** 

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 0 **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

End Item Scrap SG&A Profit ED&T-R&D Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D 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)** 

# 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**  

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb**

**#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF!**

**- $** 

**-**

**$**

**-**

**$** 

### #REF! **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!** 

**- $** 

**-**

**$**



### 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 **Ac cessory** 

**Drive Subsy stem** 

1 **00**

2 **01**

3 **02**

4 **03**

5 **05**ItemSubsystem 

# SYSTEM & SUBSYSTEM DESCRIPTION

**- $** 

**- $** 

**- $** 

**- $** 

**- $**  **Investment(X1 000)** 



### 6 **65**

7 **70**

8 **75**

9 **80**

10 **85**

11 **90**

12 **95**

13 **99**

0 **0**

0 **0**

0 **0**

0 **0**

0 **0**

0 **0 -** 

**$**

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 

**- $** 



### 0 **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

**Investment(X1 000)** 

**- $** 



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:1 of 4 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D



### 0

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$** 

# 9 **Ac cessory** 

**Drive Subsy stem** 

1 **00 Assembly of Accessory Drive Subsystem**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF!**

**- $** 



### A Assembly of Accessory Drive Subsystem 01 09 00

- N0402

- 01 1 Full 1 Only includes tensioner, tensioner spring assembly, and alternator/tensioner mounting bracket. 

### #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**

**- $** 



### 2 **01 Pulleys** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**Sub-Subsystem



### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

### System **ED&T/R&D (x1000)**  

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**

MarkupAssembly 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  **Total**

**Packaging Cost**  **(Component / Assembly)**  **Net**

**Component/ Assembly**  **Cost Impact to OEM**  

# Technology **Level:** Mild Hybrid, Start

- Stop Technology **Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

# Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

2 **01 Pulleys** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 3 **02 Tensioners**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF!**

**- $**  

### A V Tensioner, Belt 01 09 02

- N0402

- 01 1 Full 1 #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**

**- $**  

### B V Belt Tensioner Spring Assembly 01 09 02

- N0402

- 02 1 Full 1 #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**

**- $** 



### 4 **03 Guides** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 5 **05 Belts**  **4.89 $**  **1.09**

**$ 4.89** 

**$ 10.86** 

**$ 0.05** 

**$ 0.71** 

**$ 0.65** 

**$ 0.27** 

**$ 1.68** 

**$ 0.02** 

**$ 12.56** 

**$**

**-**

**$**



### A Belt - Accessory Drive 01 09 05

- N0402

- 01 1 Full 0.5 Scaled Saturn Parts service numberby factor of 2. TMC (45/10/45), Markup (0.5/6.5/6.0/2.50) 15.5%*TMC 

### 4.89 $ 1.09

$ 4.89

$ **10.86**

**$** 0.05

$ 0.71

$ 0.65

$ 0.27

$ **1.68**

**$** 0.02

$ **12.56**

**$**

**-**

**$**



### 6 **65 Adaptors** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 7 **70 Pipes, Hoses, Ducting** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 8 **75 Brackets**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF!**

**- $**  

### A V Bracket, Alternator (and Tensioner Mounting) 01 09 75

- N0402

- 01 1 Full 1 #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**

**- $** 



### 9 **80 Boltings** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### A V Large Bolt, Alt Bracket 01 09 80

- N0402

- 01 1 Full 1 PIA to Assembly of Accessory



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$** 

### A V Large Bolt, Alt Bracket 01 09 80

- N0402

- 01 1 Full 1 PIA to Assembly of Accessory Drive 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:2 of 4 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Material Labor Burden End Item Scrap SG&A Profit ED&T-R&DSub-Subsystem



### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

### System **ED&T/R&D (x1000)**  

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**

MarkupAssembly 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  **Total**

**Packaging Cost**  **(Component / Assembly)**  **Net**

**Component/ Assembly**  **Cost Impact to OEM**  

# Technology **Level:** Mild Hybrid, Start

- Stop Technology **Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

# Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

B V Bolt, Small, Alt Bracket 01 09 80

- N0402

- 02 1 Full 1 PIA to Assembly of Accessory Drive



### C V Bolt, Medium, Alt Bracket 01 09 80

- N0402

- 03 2 Full 1 PIA to Assembly of Accessory Drive



### D V Bolt Tensioner 01 09 80

- N0402

- 04 1 Full 1 PIA to Assembly of Accessory Drive


### E V Bolt, Belt Damper, Short 01 09 80

- N0402

- 05 1 Full 1 PIA to Assembly of Accessory Drive


### F V Bolt, Belt Damper Long 01 09 80

- N0402

- 06 1 Full 1 PIA to Assembly of Accessory Drive



### 10 **85 Sealing Elements** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$** 

### $ **$** $ **$ $** 



### 11 **90 Bearings Elements Misc** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 12 **95 Tools** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 13 **99 Miscellaneous** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**

**- $** 



### NOTES:


## 1. **= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of the competing technology**  Complete Subsystem Quote (Yes/No) 

## No

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:3 of 4 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

0



# 9 **Ac cessory** 

**Drive Subsy stem** 

1 **00 Assembly of Accessory Drive Subsystem** 

A Assembly of Accessory Drive Subsystem 01 09 00

- N0402

- 01 1 Full 1 Only includes tensioner, tensioner spring assembly, and alternator/tensioner mounting bracket.



### 2 **01 Pulleys** Sub-Subsystem



### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent



# NEW TECHNOLOGY GENERAL PART INFORMATION: **2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) 

# Technology **Level:** Mild Hybrid, Start

- Stop Technology **Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

# Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$ Investment**  **(X1000) Tooling**  **(x1000)**



### 2 **01 Pulleys** 

3 **02 Tensioners** 

A V Tensioner, Belt 01 09 02

- N0402

- 01 1 Full 1 B V Belt Tensioner Spring Assembly 01 09 02

- N0402

- 02 1 Full 1

4 **03 Guides** 

5 **05 Belts** 

A Belt - Accessory Drive 01 09 05

- N0402

- 01 1 Full 0.5 Scaled Saturn Parts service numberby factor of 2. TMC (45/10/45), Markup (0.5/6.5/6.0/2.50) 15.5%*TMC



### 6 **65 Adaptors** 

7 **70 Pipes, Hoses, Ducting** 

8 **75 Brackets** 

A V Bracket, Alternator (and Tensioner Mounting) 01 09 75

- N0402

- 01 1 Full 1

9 **80 Boltings** 

A V Large Bolt, Alt Bracket 01 09 80

- N0402

- 01 1 Full 1 PIA to Assembly of Accessory **- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$** 

### A V Large Bolt, Alt Bracket 01 09 80

- N0402

- 01 1 Full 1 PIA to Assembly of Accessory Drive **- $** 

**-**

**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:4 of 4 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFTSub-Subsystem



### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) 

# Technology **Level:** Mild Hybrid, Start

- Stop Technology **Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

# Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

B V Bolt, Small, Alt Bracket 01 09 80

- N0402

- 02 1 Full 1 PIA to Assembly of Accessory Drive



### C V Bolt, Medium, Alt Bracket 01 09 80

- N0402

- 03 2 Full 1 PIA to Assembly of Accessory Drive



### D V Bolt Tensioner 01 09 80

- N0402

- 04 1 Full 1 PIA to Assembly of Accessory Drive


### E V Bolt, Belt Damper, Short 01 09 80

- N0402

- 05 1 Full 1 PIA to Assembly of Accessory Drive


### F V Bolt, Belt Damper Long 01 09 80

- N0402

- 06 1 Full 1 PIA to Assembly of Accessory Drive



### 10 **85 Sealing Elements**  **Investment (X1000)**  **Tooling (x1000)** 

**- $** 

**-**

**$**

**- $** 

**-**

**$**



### 11 **90 Bearings Elements Misc** 

12 **95 Tools** 

13 **99 Miscellaneous** 

**NOTES:**


## 1. **= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of the competing technology**  Complete Subsystem Quote (Yes/No) 

## No **- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:1 of 4 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

Material Labor Burden End Item Scrap SG&A Profit ED&T-R&D



### 0

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$** 

# 9 **Ac cessory** 

**Drive Subsy stem** 

1 **00 Assembly of Accessory Drive Subsystem**  **#REF! #REF!**  **#REF! #REF!** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ #REF!** 

**- $** 



### A Assembly of Accessory Drive Subsystem 01 09 00

- B0402

- 01 1 Full 1 Used Vue hybrid cost sheet and ammended via service drawings 

### #REF! #REF! #REF! **#REF!**

- $

-

$

-

$

-

$

**-**

**$**

-

$ **#REF!**

**- $** 



### 2 **01 Pulleys** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 3 **02 Tensioners**  **4.75 $**  **2.64**

**$ 3.16** 

**$ 10.55** 

**$ 0.05** 

**$ 0.69** 

**$ 0.63** 

**$ 0.26** 

**$ 1.63** 

**$ 0.04** 

**$ 12.22** 

**$**

**-**

**$ Net**  **Component/ Assembly**  **Cost Impact to OEM**  **System**

**ED&T/R&D (x1000)**  Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

**Packaging Cost**  **(Component / Assembly)**  

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part Number Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) 

# BASE TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# Technology **Level:** Mild Hybrid, Start

- Stop Technology **Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

# Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

3 **02 Tensioners**  **4.75 $**  **2.64**

**$ 3.16** 

**$ 10.55** 

**$ 0.05** 

**$ 0.69** 

**$ 0.63** 

**$ 0.26** 

**$ 1.63** 

**$ 0.04** 

**$ 12.22** 

**$**

**-**

**$**



### A Tensioner - 2.2 Liter Saturn Vue 01 09 02

- B0402

- 01 1 Full 0.18 Scaled service price based on ratio developed for Vue Hybrid developed cost versus service cost (5.6 Factor). Kept same cost element binning ratios. 

### 4.75 $ 2.64

$ 3.16

$ **10.55**

**$** 0.05

$ 0.69

$ 0.63

$ 0.26

$ **1.63**

**$** 0.04

$ **12.22**

**$**

**-**

**$**



### 4 **03 Guides** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 5 **05 Belts**  **2.85 $**  **0.63**

**$ 2.85** 

**$ 6.33** 

**$ 0.03** 

**$ 0.41** 

**$ 0.38** 

**$ 0.16** 

**$ 0.98** 

**$ 0.02** 

**$ 7.33** 

**$**

**-**

**$**



### A Belt - Accessory Drive 2.2 L Saturn Vue 01 09 05

- B0402

- 01 1 Full 0.5 Scaled Saturn Parts service numberby factor of 2. TMC (45/10/45), Markup (0.5/6.5/6.0/2.50) 15.5%*TMC 

### 2.85 $ 0.63

$ 2.85

$ **6.33**

**$** 0.03

$ 0.41

$ 0.38

$ 0.16

$ **0.98**

**$** 0.02

$ **7.33**

**$**

**-**

**$**



### 6 **65 Adaptors** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 7 **70 Pipes, Hoses, Ducting** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 8 **75 Brackets**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF! #REF!**  **#REF!**

**- $** 



### A V Bracket, Alternator (and Tensioner Mounting) 01 09 75

- B0402

- 01 1 Full 0.75 Scaled Vue Hybrid developed cost to account for less mounting content. #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**

**- $** 



### 9 **80 Boltings** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### A V Large Bolt, Alt Bracket 01 09 80

- B0402

- 01 1 Full 1 PIA to Assembly of Accessory Drive 

### - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:2 of 4 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

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)**  Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

**Packaging Cost**  **(Component / Assembly)**  

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part Number Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) 

# BASE TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# Technology **Level:** Mild Hybrid, Start

- Stop Technology **Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

# Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

B V Bolt, Small, Alt Bracket 01 09 80

- B0402

- 02 1 Full 1 PIA to Assembly of Accessory Drive



### C V Bolt, Medium, Alt Bracket 01 09 80

- B0402

- 03 1 Full 1 PIA to Assembly of Accessory Drive



### D V Bolt Tensioner 01 09 80

- B0402

- 04 1 Full 1 PIA to Assembly of Accessory Drive



### 10 **85 Sealing Elements** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 11 **90 Bearings Elements Misc** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 12 **95 Tools** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### 13 **99 Miscellaneous** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



### #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**

**- $** 



### NOTES:


## 1. Complete Subsystem Quote (Yes/No) 

## N

**= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of the competing technology** 

09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:3 of 4 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT

0



# 9 **Ac cessory** 

**Drive Subsy stem** 

1 **00 Assembly of Accessory Drive Subsystem** 

A Assembly of Accessory Drive Subsystem 01 09 00

- B0402

- 01 1 Full 1 Used Vue hybrid cost sheet and ammended via service drawings



### 2 **01 Pulleys** 

3 **02 Tensioners**  

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part Number Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1)QTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Mild Hybrid, Start

- Stop Technology **Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

# Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$ Investment**  **(X1000) Tooling**  **(x1000)**



### 3 **02 Tensioners** 

A Tensioner - 2.2 Liter Saturn Vue 01 09 02

- B0402

- 01 1 Full 0.18 Scaled service price based on ratio developed for Vue Hybrid developed cost versus service cost (5.6 Factor). Kept same cost element binning ratios.



### 4 **03 Guides** 

5 **05 Belts** 

A Belt - Accessory Drive 2.2 L Saturn Vue 01 09 05

- B0402

- 01 1 Full 0.5 Scaled Saturn Parts service numberby factor of 2. TMC (45/10/45), Markup (0.5/6.5/6.0/2.50) 15.5%*TMC



### 6 **65 Adaptors** 

7 **70 Pipes, Hoses, Ducting** 

8 **75 Brackets** 

A V Bracket, Alternator (and Tensioner Mounting) 01 09 75

- B0402

- 01 1 Full 0.75 Scaled Vue Hybrid developed cost to account for less mounting content.

9 **80 Boltings**  **- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



### A V Large Bolt, Alt Bracket 01 09 80

- B0402

- 01 1 Full 1 PIA to Assembly of Accessory Drive **- $** 

**-**

**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page:4 of 4 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/23/2012 DRAFT



# BASE TECHNOLOGY GENERAL PART INFORMATION: **2007 Saturn Vue, 2.4L I4, 170hp, 162 ft-lb**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part Number Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1)QTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# Technology **Level:** Mild Hybrid, Start

- Stop Technology **Vehicle Class:** Mid to Large Size Passenger Vehilce, 4

- 6 Passengers 

# Study Case#: B0402 (N=New, B=Base, 04=Technology Package, 02=Vehicle Class)

B V Bolt, Small, Alt Bracket 01 09 80

- B0402

- 02 1 Full 1 PIA to Assembly of Accessory Drive



### C V Bolt, Medium, Alt Bracket 01 09 80

- B0402

- 03 1 Full 1 PIA to Assembly of Accessory Drive



### D V Bolt Tensioner 01 09 80

- B0402

- 04 1 Full 1 PIA to Assembly of Accessory Drive



### 10 **85 Sealing Elements** 

11 **90 Bearings Elements Misc**  **Investment (X1000)**  **Tooling (x1000)** 

**- $** 

**-**

**$**

**- $** 

**-**

**$**



### 12 **95 Tools** 

13 **99 Miscellaneous** 

**NOTES:**


## 1. Complete Subsystem Quote (Yes/No) 

## N

**= A highlighted Sub-subsystem, Assembly or Component row indicates design and/or manufacturing differentials are accounted for in the quote sheet of the competing technology**  **- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



### 09000064810ec171.xls EPA Contract:EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 1 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)**  

## Annual Component Volume: Shipping Method: **Component Description: Part Number:**  We ekly Component Volume: Packaging Specification: **Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material

A 

## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00** 

### 9,574

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000** 

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Hybrid - Start-Stop Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### B 

## Purchase Part - High Impact Item (Full Cost Mapping)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 2 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)**  

## Annual Component Volume: Shipping Method: **Component Description: Part Number:**  We ekly Component Volume: Packaging Specification: **Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000** 

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Hybrid - Start-Stop Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### C 

## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process)

1 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
2 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
3 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
4 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
5 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
6 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

7 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
9 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
10 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
11 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
12 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
13 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
14 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
15 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
16 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
17 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
19 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
20 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
21 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
22 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
23 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
24 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
25 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
26 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
27 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
28 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
29 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**
30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 3 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)**  

## Annual Component Volume: Shipping Method: **Component Description: Part Number:**  We ekly Component Volume: Packaging Specification: **Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000** 

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Hybrid - Start-Stop Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**



### D 

## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Supplier Account**  **Cost Purchase** 

**Price/ Unit**  **Purchase**

**Price Net, PIA**  **Purchase**

**Price Net, End Item** 

1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

2 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

5 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
6 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

7 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### "S"=Indicates Component is Supplied directly to T1 or OEM for Final or Sub

Assembly.

"SAC"=(Supplier Accounted Costs) Indicates Component is Supplied directly to T1 or OEM for Final or Sub

- Assembly. In addition component material cost is accounted for in T1 quote sheet. Thus component cost will only be included for Mark

- up Calculations.

"Alpha

- Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly. 9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
10 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

11 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

12 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

21 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

22 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
23 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

24 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
25 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
26 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

27 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
28 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
29 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**
30 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

**Material**

**$0.00**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$0.00**

**T1 or OEM Total Manufacturing Cost: $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

**T1 or OEM Mark-Up Rates:**

----- ----- ----- ----- #N/A #N/A #N/A #N/A #N/A 

### Supplier for Subassembly.

**3 1** 



### Notes: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error. T1 or OEM Mark-Up Rates:** 

----- ----- ----- ----- #N/A #N/A #N/A #N/A #N/A **(SAC) &T1 or OEM Mark-Up Values:**  **0.00**

----- ----- ----- **#N/A #N/A**  **#N/A #N/A**  **#N/A**
**Base Cost Impact to Vehicle: $0.00**  **$0.00 $0.00**  **$0.00 #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0**  **$0 Packaging Cost:**  **$0.00 Net Cost Impact to Vehicle:**  **#N/A a) Items 1,2, & 3 must all equal same value otherwise**  **there is a computation error.** 



### Reference Packaging Database for Additonal Infromation Maximum Pallet Stack Height = 100" Pallet Options



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 4 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

## Annual Engine Volume (CPV): Supplier Plant Location: **Study Case#: N0402 (N = New, 04 = Technology Package, 02 = Vehicle Class )**  

## Components per Engine: OEM/T1 Classification: **System Description: 2007 Saturn Vue, 2.4L, I4, 170 hp, Mild HEV (Electric Motor 14.5kW, Battery 36V, Nominal Pack Capacity 18.4Ah)**  

## Annual Component Volume: Shipping Method: **Component Description: Part Number:**  We ekly Component Volume: Packaging Specification: **Component Quote Level:** Estimated Product Life: Production Year: **2008/2009**

**Item R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number Q** **T Y** **P e** **r A** **s s** **e m** **b l** **y** 

### Primary Process **Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

**Classification F** **i n** **i s** **h e** **d P** **i e** **c e** **s P** **e r** **H o** **u r** **N u** **m b** **e r** **o f** **O p** **e r** **a t** **o r** **s N** **u m** **b e** **r o** **f L** **i n** **e s** **P a** **r a** **l l** **e l** **P r** **o c** **e s** **s i** **n g** **M u** **l t** **i p** **l i** **e r** **M a** **t e** **r i** **a l** **U s** **a g** **e "** **l b** **s "**  

### Material **Cost $/lb**  **(DB) Labor**  **Rate $/Hour**  **(DB) Burden**  **Rate $/Hour**  **(DB) Applied**  **Burden Rate**  **$/Hour Material** 

**Cost Labor/ Part**  **Burden/**

**Part T** **o t** **a l** **1 =** **M a** **t e** **r i** **a l** **+ L** **a b** **o r** **+ B** **u r** **d e** **n** 

### End

**Item Scrap**  **Rate (DB)**  **SG&A Rate**  **(DB) Profit**  **Rate (DB)**  **ED&T/ R&D**  **Rate (DB)**  **Total Mark**  **up Rate**  **Total Mark**  **up Cost** **T o** **t a** **l 2** **= T** **o t** **a l** **1 +** **T o** **t a** **l M** **a r** **k -** **u p** **T o** **t a** **l 3** **= T** **o t** **a l** **2*********Q t** **y p** **e r** **A s** **s '** **y T** **o o** **l i** **n g** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "** **I n** **v e** **s t** **m e** **n t** **A s** **s u** **m p** **t i** **o n** **s "** **x 1** **0 0** **0 "**  

### Material **9,574**

**10 North America** 
**North America**

**FOB Ship Point 47**  **450,000**
**1 450,000** 

**GENERAL COMPONENT INFORMATION GENERAL MANUFACTURING INFORMATION**  **MANUFACTURING COSTS MANUFACTURING RATES**  **Mild Hybrid - Start-Stop Technology**

**MARK-UP COSTS Manufacturing Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account TOTAL COSTS**  **TOOLING & INVESTMENT** 

### 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.

**Ful l Qu**  **ote Modification Quote**  

### Di **ffe ren**  **tial Qu ote (Quote S**  **um ma**  **ry includes costing for both T ech**  **nol ogy P**  **ackages)**

**Packaging Cost per**  **Piece Total** 

**Amount Lump Sum** 

**Payment (%)**  **Total # of**

**Pieces Number of** 

**Months Interest** 

**Rate C** **o s** **t p** **e r** **P a** **l l** **e t** **/ R** **a c** **k T** **o t** **a l** **N u** **m b** **e r** **o f** **P a** **l l** **e t** **s /** **R a** **c k** **s R** **e q** **u i** **r e** **d N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **R a** **c k** **S u** **p p** **l i** **e r** **, C** **u s** **t o** **m e** **r a** **n d** **I n** ******t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( W** **e e** **k s** **) S** **u p** **p l** **i e** **r ,** **C u** **s t** **o m** **e r** **a n** **d I** **n********t r** **a n** **s i** **t I** **n v** **e n** **t o** **r y** **R e** **q u** **i r** **e m** **e n** **t s** **( P** **a r** **t s** **)**



### Rack/Pallet Investment Amortization: **$0.000 $0**  **0.00% 2,250,000**  **60 5.00%**  $0 **58** 1000 **6 57447** 

**Packaging Cost per**  **Piece Tier Pad**  **Price Per Tier Pads** 

**Pallet/Rack Divider Pads,** 

**Price Per Divider Pads** 

**Pallet/Rack Other #1** 

**Packaging Price Per**  **Other #1**

**Pads Pallet/Rack**  **Other #2**

**Packaging Price Per**  **Other #2**

**Pads Pallet/Rack**  **Other #3**

**Packaging, Price Per**  **Other #3**

**Pads Pallet/Rack** 



### Expendable Packaging in Piece Cost: **$0.00** $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 

### PACKAGING CALCULATIONS: Packaging Type: Part Size: Parts/Layer: Number of Layers: Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.) Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote **Expendable Packaging in Piece Cost: $0.00**  $0.00 0 $0.00 0 $0.00 0 $0.00 0 $0.00 0 

### Packaging Cost Total: **$0.000** 

### Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base
Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.) Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.) ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00 Returnable Dividers For Option 1 Pallet

- 8 Cells (2x4)xHeight of Pallet, =$20.00



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 5 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**



## Purchase Part - High Impact Item (Full Cost Mapping) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 6 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **#DIV/0! #DIV/0!**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 7 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



## Purchase Part - Commodity ( Value taken from Purchase Part Database) **Labor Burden** **T o** **t a** **l M** **f g** **' i** **n g** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**Labor Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up**  **Total**
**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$0.00 2** 



### Notes: **a) Items 1,2, & 3 must all equal same value otherwise there is a computation**  **error.**



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 8 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



### Labor **Burden T** **o t** **a l** **M f** **g '** **i n** **g C** **o s** **t (** **C o** **m p** **o n** **e n** **t /** **A s** **s e** **m b** **l y** **)** 

### End Item **Scrap SG&A**  **Profit ED&T**  **R&D T** **o t** **a l** **M a** **r k** **u p** **C o** **s t** **( C** **o m** **p o** **n e** **n t** **/ A** **s s** **e m** **b l** **y )**  

### Process & Equipment Assumptions **Tool, Fixture and Gauge Assumptions Days/**  **Week Shifts./**  **Day Hrs./**  **Shift Hrs./**  **Wk Wks./**  **Yr. Hrs./**  **Yr. P** **c s** **. .** **/ H** **r .** **( 1** **0 0** **% E** **f f** **. .** **) C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **" S** **e c** **. "** **E f** **f i** **c i** **e n** **c y** **% P** **c s** **. .** **/ H** **r .** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y C** **y c** **l e** **T i** **m e** **/ O** **p e** **r a** **t i** **o n** **@ S** **t a** **t e** **d E** **f f** **i c** **i e** **n c** **y "** **S e** **c .** **" L** **e a** **n D** **e s** **i g** **n C** **a l** **c u** **l a** **t i** **o n** **f o** **r C** **o m** **p l** **e t** **e P** **r o** **c e** **s s** **T i** **m e** **" S** **e c** **. "** **P a** **r a** **l l** **e l** **O p** **e r** **a t** **i o** **n s** **/ M** **a c** **h i** **n e** **o r** **S t** **a t** **i o** **n s** **/ L** **i n** **e P** **i e** **c e** **/ C** **y c** **l e** **/ M** **a c** **h i** **n e** **T a** **c k** **T i** **m e** **/ M** **a c** **h i** **n e** **/ C** **y c** **l e** **" S** **e c** **o n** **d s** **" M** **u l** **t i** **p l** **i e** **r ,** **I f** **R e** **q u** **i r** **e d** **f o** **r P** **a r** **a l** **l e** **l P** **r o** **c e** **s s** **i n** **g (** **1 =** **N o** **t h** **i n** **g )** **N u** **m b** **e r** **o f** **E q** **u i** **v a** **l e** **n t** **M a** **c h** **i n** **e s** **R e** **q u** **i r** **e d**  

### Projected Operating Pattern **Minimum Calculated Cycles Time MANUFACTURING ASSUMPTIONS**  **Manufacturing Costs x Quantity Project Process Requirement**  **Process Information Gross Mark-up Costs x Quantity**  **Costs Broken Out Into Categories with Quantity per Assembly Taken into Account**

File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 9 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number**



## Tier 1 Supplier or OEM Processing & Assembly (Full Cost mapping)

**GENERAL COMPONENT INFORMATION** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

-



## Purchase Part - High Impact Item (Full Cost Mapping) **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

-



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 10 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 

**#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

-



## Purchase Part - Low Impact Item ( Partial Cost Mapping = Processed Raw Material Estimate + Actual Component Assembly Process) **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

-

**#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

- **#DIV/0! #DIV/0!** 

-



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 11 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



## Purchase Part - Commodity ( Value taken from Purchase Part Database)**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411

### Page: 12 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/23/2012 DRAFT 

## Technology Level: **Vehicle Class: Study Case#:**  **System Description: Component Description:**  **Component Quote Level: R** **e f** **e r** **e n** **c e** **#** 

### Part Description **Part Number GENERAL COMPONENT INFORMATION**  1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.**R e** **s u** **l t** **i n** **g P** **i e** **c e** **s /** **H o** **u r** **R e** **s u** **l t** **i n** **g C** **y c** **l e** **T i** **m e** **/ P** **a r** **t "** **S e** **c .** **T o** **t a** **l N** **u m** **b e** **r o** **f D** **i r** **e c** **t O** **p e** **r a** **t o** **r s** 



### File:09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONFIDENTIAL Form Author: G. Kolwich (248)373-6000 Ext. 2411