# Page:1 of 6 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/23/2012

DRAFT

Material Labor Burden End Item

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



# 0 **n/a n/a** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# 060600 Brake A **ctuation Subsy stem** 

1 **00 Vehicle Installation of Brake Actuation Subsystem**  **0.30 $**  **1.22**

**$ 0.19** 

**$ 1.71** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 1.71** 

**$**

**-**

**$**



# A Vehicle Installation of Brake Actuation Subsystem Components 06 06 00

- B0502

- 01 1 Mod. 1 Baseline ($) for Brake Pedal

Assembly. Added assembly cost for

Brake Pressure Control Valve & line

connections. 

# 0.30 $ 1.22

$ 0.19

$ **1.71**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **1.71**

**$**

**-**

**$**



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**Sub-Subsystem



# Part Number 

# BASE TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

# Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)**SubassemblyComponent 

# System

**ED&T/R&D**

**(x1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem 

# BASE 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:** Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers



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

2 **01 Master Cylinder and Reservoir** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



# A H Master Cylinder 06 06 01

- B0502

- 01 1 na 1 Bore and Stroke are slightly

different, however it is estimated

they would be very similar in cost. 

# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# 3 **02 Pedals**  **5.44 $**  **1.84**

**$ 5.97** 

**$ 13.25** 

**$ 0.07** 

**$ 0.95** 

**$ 0.85** 

**$ 0.33** 

**$ 2.20** 

**$ 0.10** 

**$ 15.55** 

**$**

**-**

**$**



# A H Brake Pedal Assembly 06 06 02

- B0502

- 01 1 Full 1 Brake-by-wire versus traditional

pedal and bracket assembly brake in

base vehicle. 

# 5.44 $ 1.84

$ 5.97

$ **13.25**

**$** 0.07

$ 0.95

$ 0.85

$ 0.33

$ **2.20**

**$** 0.10

$ **15.55**

**$**

**-**

**$**



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# 4 **03 Brake Lines and Hoses**  **0.89 $**  **0.38**

**$ 1.28** 

**$ 2.55** 

**$ 0.01** 

**$ 0.17** 

**$ 0.20** 

**$ 0.06** 

**$ 0.44** 

**$**

**-**

**$ 2.99** 

**$**

**-**

**$**



# A Brake Line Assembly #1- HCU to Control valve 06 06 03

- B0502

- 01 2 Mod 1 Only accounting for added fitting and

assembly cost to split line versus

solid line on HEV.

Est. $0.75/Joint 

# 0.45 $ 0.19

$ 0.64

$ **1.28**

**$** 0.00

$ 0.08

$ 0.10

$ 0.03

$ **0.22**

**$**

-

$ **1.50**

**$**

**-**

**$**



# B Brake Line Assembly #2- HCU to Control valve 06 06 03

- B0502

- 02 2 Mod 1 Only accounting for added fitting and

assembly cost to split line versus

solid line on HEV.

Est. $0.75/Joint 

# 0.45 $ 0.19

$ 0.64

$ **1.28**

**$** 0.00

$ 0.08

$ 0.10

$ 0.03

$ **0.22**

**$**

-

$ **1.50**

**$**

**-**

**$**



# 5 **05 Brake Control Valves** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



# A Brake Pressure Control Valve 06 06 05

- B0502

- 01 1 Full 1 HEV able to delete due to regen -

braking through front wheels in

regen mode. 

# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# 6 **06 Brake Fluid** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# 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&DSub-Subsystem



# Part Number 

# BASE TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

# Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)**SubassemblyComponent 

# System

**ED&T/R&D**

**(x1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem 

# BASE 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:** Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers



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

- $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# 7 **10 TBD** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# 8 **60 Wiring Harness Connections** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



# A Wire Harness - Solenoid, Brake Pedal Cut-off Value (XX Pins) 

# 06 06 60

- B0502

- 01 1 na 1 Base Brake Pedal, Not Required



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# B Wire Harness - Pressure Sensor, Brake Pedal Cutt-off Valve (XX Pins) 

# 06 06 60

- B0502

- 02 1 na 1 Base Brake Pedal, Not Required



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# C Wire Harness - Angle Sensor, Brake Pedal & Bracket Assembly (XX Pins) 

# 06 06 60

- B0502

- 03 1 na 1 Base Brake Pedal, Not Required



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# D Wire Harness - Brakelamp/Redundant Cruise Deact (4 Pins) 

# 06 06 60

- B0502

- 04 1 na 1 Required for both Base and HEV

Configuration. 

# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# 9 **70 Pipes, Hoses, Ducting** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# 10 **75 Brackets** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



# A Bracket - Brake Pedal 06 06 75

- B0502

- 01 1 na 1 Base Brake Pedal, Not Required



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# 11 **80 Boltings** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



# A Nut - Pedal & Bracket Assembly Brake to Booster 06 06 80

- B0502

- 01 4 na 1 Required for both Base and HEV

Configuration. 

# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# B Bolt - Pedal & Bracket Assembly Brake to Int.Cowl Brkt 06 06 80

- B0502

- 02 2 na 1 Required for both Base and HEV

Configuration. 

# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# C Bolt - Cowl Int. Brkt to Cowl Brkt. (Same as B) 06 06 80

- B0502

- 03 2 na 1 Base Brake Pedal, Not Required



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# D Bolt - Brake Pressure Control Valve 06 06 80

- B0502

- 04 2 Full 1 Only required for Base, HEV

handles brake loading via regen.

**PIA to Vehicle Installation**

. 

# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# 12 **85 Sealing Elements** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# 13 **90 Bearings Elements Misc** 

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# 14 **99 Miscellaneous**  **0.50 $** 

**-**

**$**

**-**

**$ 0.50** 

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$ 0.50** 

**$**

**-**

**$**



# A Switch - Brake Lamp and Redundant Cruise Deact 06 06 99

- B0502

- 01 1 na 1 Same for Base and HEV



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# B Pin - Booster Clevis 06 06 99

- B0502

- 02 1 Full 1 Standard Clevis Pin for Base 

# 0.35 $

-

$

-

$ **0.35**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **0.35**

**$**

**-**

**$**



# C Clip - Pin, Booster Clevis 06 06 99

- B0502

- 03 1 Full 1 Standard J-Clip 

# 0.15 $

-

$

-

$ **0.15**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$ **0.15**

**$**

**-**

**$**



# 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

Material Labor Burden End Item

Scrap SG&A Profit ED&T-R&DSub-Subsystem



# Part Number 

# BASE TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

# Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)**SubassemblyComponent 

# System

**ED&T/R&D**

**(x1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem 

# BASE 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:** Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers



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

7.13 $ 3.44

$ 7.43

$ **18.01**

**$** 0.08

$ 1.11

$ 1.06

$ 0.40

$ **2.64**

**$** 0.10

$ **20.75**

**$**

**-**

**$**



# 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:4 of 6 

# COST MODEL ANALYSIS TEMPLATE

**Light-Duty Technology Cost Study**

**EP-C-07-069 WA1-3** Printed: 8/23/2012

DRAFT

0 **n/a n/a** 



# 060600 Brake A **ctuation Subsy stem** 

1 **00 Vehicle Installation of Brake Actuation Subsystem** 

A Vehicle Installation of Brake Actuation Subsystem Components 06 06 00

- B0502

- 01 1 Mod. 1 Baseline ($) for Brake Pedal

Assembly. Added assembly cost for

Brake Pressure Control Valve & line

connections.Sub-Subsystem



# Part NumberQTY/Subsystem 

# NotesSubassemblyComponent 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



# Name/Description Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor

(Default =1) 

# Technology **Level:** Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers



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

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$ Investment** 

**(X1000) Tooling** 

**(x1000)**



# 2 **01 Master Cylinder and Reservoir** 

A H Master Cylinder 06 06 01

- B0502

- 01 1 na 1 Bore and Stroke are slightly

different, however it is estimated

they would be very similar in cost.



# 3 **02 Pedals** 

A H Brake Pedal Assembly 06 06 02

- B0502

- 01 1 Full 1 Brake-by-wire versus traditional

pedal and bracket assembly brake in

base vehicle.



# 4 **03 Brake Lines and Hoses** 

A Brake Line Assembly #1- HCU to Control valve 06 06 03

- B0502

- 01 2 Mod 1 Only accounting for added fitting and

assembly cost to split line versus

solid line on HEV.

Est. $0.75/Joint



# B Brake Line Assembly #2- HCU to Control valve 06 06 03

- B0502

- 02 2 Mod 1 Only accounting for added fitting and

assembly cost to split line versus

solid line on HEV.

Est. $0.75/Joint



# 5 **05 Brake Control Valves** 

A Brake Pressure Control Valve 06 06 05

- B0502

- 01 1 Full 1 HEV able to delete due to regen -

braking through front wheels in

regen mode. 

# - **$**

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



# 6 **06 Brake Fluid** 

**- $** 

**-**

**$**

**- $** 

**-**

**$**



# 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

DRAFTSub-Subsystem



# Part NumberQTY/Subsystem 

# NotesSubassemblyComponent 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



# Name/Description Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor

(Default =1) 

# Technology **Level:** Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers



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

7 **10 TBD** 

8 **60 Wiring Harness Connections** 

A Wire Harness - Solenoid, Brake Pedal Cut-off Value (XX Pins) 

# 06 06 60

- B0502

- 01 1 na 1 Base Brake Pedal, Not Required



# B Wire Harness - Pressure Sensor, Brake Pedal Cutt-off Valve (XX Pins) 

# 06 06 60

- B0502

- 02 1 na 1 Base Brake Pedal, Not Required



# C Wire Harness - Angle Sensor, Brake Pedal & Bracket Assembly (XX Pins) 

# 06 06 60

- B0502

- 03 1 na 1 Base Brake Pedal, Not Required



# D Wire Harness - Brakelamp/Redundant Cruise Deact (4 Pins) 

# 06 06 60

- B0502

- 04 1 na 1 Required for both Base and HEV

Configuration.



# 9 **70 Pipes, Hoses, Ducting**  **Investment**

**(X1000) Tooling** 

**(x1000)**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



# 10 **75 Brackets** 

A Bracket - Brake Pedal 06 06 75

- B0502

- 01 1 na 1 Base Brake Pedal, Not Required



# 11 **80 Boltings** 

A Nut - Pedal & Bracket Assembly Brake to Booster 06 06 80

- B0502

- 01 4 na 1 Required for both Base and HEV

Configuration.



# B Bolt - Pedal & Bracket Assembly Brake to Int.Cowl Brkt 06 06 80

- B0502

- 02 2 na 1 Required for both Base and HEV

Configuration.



# C Bolt - Cowl Int. Brkt to Cowl Brkt. (Same as B) 06 06 80

- B0502

- 03 2 na 1 Base Brake Pedal, Not Required



# D Bolt - Brake Pressure Control Valve 06 06 80

- B0502

- 04 2 Full 1 Only required for Base, HEV

handles brake loading via regen.

**PIA to Vehicle Installation**

.



# 12 **85 Sealing Elements** 

13 **90 Bearings Elements Misc** 

14 **99 Miscellaneous** 

A Switch - Brake Lamp and Redundant Cruise Deact 06 06 99

- B0502

- 01 1 na 1 Same for Base and HEV



# B Pin - Booster Clevis 06 06 99

- B0502

- 02 1 Full 1 Standard Clevis Pin for Base 

# - **$**

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**

**- $** 

**-**

**$**



# C Clip - Pin, Booster Clevis 06 06 99

- B0502

- 03 1 Full 1 Standard J-Clip



# - **$**

**-**

**$**



# 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

DRAFTSub-Subsystem



# Part NumberQTY/Subsystem 

# NotesSubassemblyComponent 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



# Name/Description Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor

(Default =1) 

# Technology **Level:** Power

- Split HEV Technology

**Vehicle Class:** Mid to Large Size Passenger Vehicle, 4

- 6 Passengers



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

**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 **Investment**

**(X1000) Tooling** 

**(x1000)**

**- $** 

**-**

**$**



# 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#: B0502 (B = Base, 05 = Technology Package, 02 = Vehicle Class )**  

# Components per Engine: OEM/T1 Classification: **OEM Vehicle Assembly**



# System Description: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: Vehicle Installation of Brake Actuation Subsystem Components**  

# Part Number: **060600-B0502-01** 

# We ekly Component Volume: Packaging Specification: **n/a**



# 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 1A Vehicle Installation of Brake Pressure Control

Valve 060600-B0502-01-01 **1** Load & R/D two places 

# OEM Vehicle Assembly Not Applicable General Assembly-OEM 

# VO Assembly, OEM, LC **240 1**  **1 1**  0.000 **$0.00 $97.48**  **$15.00 $15.00**  **$0.00 $0.41**  **$0.06 $0.47**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.47 $0.47**  **$0.00**

2 2A Vehicle Installation of Brake Pressure Control

Valve Brake Line 060600-N0502-01-02 **1** Hand Start, Manual R/D 

# OEM Vehicle Assembly Not Applicable General Assembly-OEM 

# VO Assembly, OEM, LC **240 2**  **2 1**  0.000 **$0.00 $97.48**  **$15.00 $30.00**  **$0.00 $0.81**  **$0.13 $0.94**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.94 $0.94**  **$0.00**

3 **0 #####**  **0 2**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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** 

# 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)**

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**



# 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 3**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00**

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

4 **0 #####**  **0 2**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #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**

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 (B = Base, 05 = Technology Package, 02 = Vehicle Class )**  

# Components per Engine: OEM/T1 Classification: **OEM Vehicle Assembly**



# System Description: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: Vehicle Installation of Brake Actuation Subsystem Components**  

# Part Number: **060600-B0502-01** 

# We ekly Component Volume: Packaging Specification: **n/a**



# 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)**

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 **$0.99 #N/A**  **#N/A #N/A**  **$0.00 #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 **$0.99 #N/A**  **#N/A #N/A**  **$0.00 #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**



# 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 A Bolt - Brake Pressure Control Valve 060680-B0502-04 **2** S **$0.00** $0.15 **$0.00 $0.30**  **$0.30** 

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



# 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 (B = Base, 05 = Technology Package, 02 = Vehicle Class )**  

# Components per Engine: OEM/T1 Classification: **OEM Vehicle Assembly**



# System Description: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: Vehicle Installation of Brake Actuation Subsystem Components**  

# Part Number: **060600-B0502-01** 

# We ekly Component Volume: Packaging Specification: **n/a**



# 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)**

2 B **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

3 C **0 $0.00**  $0.000 **$0.00 $0.00**  **$0.00**

4 D **0 $0.00**  $0.000 **$0.00 $0.00**  **$0.00**

5 E **0 $0.00**  $0.000 **$0.00 $0.00**  **$0.00**

6 F **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

7 G **0 $0.00**  $0.000 **$0.00 $0.00**  **$0.00**

8 H **0 $0.00**  $0.000 **$0.00 $0.00**  **$0.00**

9 I **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

10 J **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

11 K **0 $0.00**  $0.000 **$0.00 $0.00**  **$0.00**

12 L **0 $0.00**  $0.000 **$0.00 $0.00**  **$0.00**

13 M **0 $0.00**  $0.000 **$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.

13 M **0 $0.00**  $0.000 **$0.00 $0.00**  **$0.00**

14 N **0 $0.00**  $0.000 **$0.00 $0.00**  **$0.00**

15 O **0 $0.00**  $0.000 **$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**

**Material**

**$0.30**

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

**Mark-up $1.71** 

**T1 or OEM Total Manufacturing Cost: $0.30**  **$1.22 $0.19**  **$1.71 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$1.71**

**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: $0.30**  **$1.22 $0.19**  **$1.71 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$1.71 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $1.71**  **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"

**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: 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



# 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 (B = Base, 05 = Technology Package, 02 = Vehicle Class )**  

# Components per Engine: OEM/T1 Classification: **OEM Vehicle Assembly**



# System Description: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: Vehicle Installation of Brake Actuation Subsystem Components**  

# Part Number: **060600-B0502-01** 

# We ekly Component Volume: Packaging Specification: **n/a**



# 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 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, 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: 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)

1A Vehicle Installation of Brake Pressure Control

Valve 060600-B0502-01-01

2A Vehicle Installation of Brake Pressure Control

Valve Brake Line 060600-N0502-01-02



# 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** 



# $0.41 **$0.06 $0.47**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Operator position "Brake Pressure Control Valve ", manual R/D two places. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- 1 1 15 **1.0 1.0** 

**$0.81 $0.13**  **$0.94 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Load Brake lines into Brake Pressure Control Valve and R/D, 4 Plcs. **5 2**  **10 100**  **47 4700**  **96 37.60**  **85% 113**  **31.96**

- 1 1 30 **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 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**  

# 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 3.0** 

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

- - - - **1.1 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** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $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** 



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

A Bolt - Brake Pressure Control Valve 060680-B0502-04 **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.30**



# 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.

B

C

D

E

F

G

H

I

J

K

L

M 

# 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** M

N

O **$0.00**

**$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**

**$1.22 $0.19**  **$1.71 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$1.71 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)

1A Vehicle Installation of Brake Pressure Control

Valve 060600-B0502-01-01

2A Vehicle Installation of Brake Pressure Control

Valve Brake Line 060600-N0502-01-02



# 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** 



# 240 **15.00** 1.00

**240 15.00**  2.00

**#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!** 

-



# 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)

A Bolt - Brake Pressure Control Valve 060680-B0502-04 **#DIV/0! #DIV/0!** 

-

**#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.

B

C

D

E

F

G

H

I

J

K

L

M**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** 



# M

N

O



# 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 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

**- $** 

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**

**-**

**$**



# - $

-

$

-

$

**-**

**$**

-

$

-

$

-

$

-

$

**-**

**$**

-

$

**-**

**$**

**-**

**$**



# 06 **02 G Brake Pedal A**  **ssembly 06**  **06 02** 

**- B0502** 

**- 01**  **1** 0.08 $ 0.34

$ 0.26

$ **0.68**

**$** 0.00

$ 0.04

$ 0.04

$ 0.02

$ 0.11

$ 0.10

$ **0.88**

**$ 0.79** 

**$**

G Brake Mounting Bracket Asm. 

# 06 06 02

- B0502

- 02 1 Not Mapped - Beyond Scope

G Bolt, Brake Mounting Bracket 

# 06 06 02

- B0502

- 03 2 PIA



# A **G Pedal Box Asm.** 

# 06 06 02

- B0502

- 04 1 0.16 $ 0.34

$ 0.26

$ **0.76**

**$** 0.00

$ 0.05

$ 0.05

$ 0.02

$ 0.12

$

-

$ **0.88**

**$ 0.88** 

**$**

G Bolt, Long, Spacer 

# 06 06 02

- B0502

- 05 1 PIA

G Nut, Spacer 

# 06 06 02

- B0502

- 06 1 PIA



# B **G Spacer, Lever and Support Asm.** 

# 06 06 02

- B0502

- 07 1 0.06 $ 0.01

$ 0.01

$ **0.07**

**$** 0.00

$ 0.01

$ 0.01

$ 0.00

$ 0.02

$

-

$ **0.09**

**$ 0.09** 

**$**



# C **G Bracket, Pedal Stop, Asm.** 

# 06 06 02

- B0502

- 08 1 0.56 $ 0.07

$ 0.61

$ **1.24**

**$** 0.01

$ 0.08

$ 0.07

$ 0.03

$ 0.19

$

-

$ **1.43**

**$ 1.43** 

**$**

G Bracket, Pedal Stop 

# 06 06 02

- B0502

- 09 1 PIA

G Tab, Bracket, Pedal Stop 

# 06 06 02

- B0502

- 10 1 PIA 

# BASE TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

# Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)**SubassemblyComponentSub-Subsystem 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



# Name/Description Part Number Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor

(Default =1) **Net**

**Component/**

**Assembly**

**Cost Impact to**

**OEM System** 

**ED&T/R&D**

**(x1000)** Markup

**Total Markup**

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly)** 

# Technology **Level: Parallel HEV Technology** 

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4** 

**- 6 Passengers** 

**Study Case#:**  **B0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)**

G Tab, Bracket, Pedal Stop 

# 06 06 02

- B0502

- 10 1 PIA

G W eld Nut, Bracket, Stop 

# 06 06 02

- B0502

- 11 1 PIA



# D **G Pedal Stop Asm.** 

# 06 06 02

- B0502

- 12 1 0.56 0.07 0.61 **1.24** 0.01 0.08 0.07 0.03 0.19

- $ **0.27**

**$ 1.43** 

**$**

G Bolt, Short, Pedal Stop 

# 06 06 02

- B0502

- 13 1 PIA

G Nut, Pedal Stop 

# 06 06 02

- B0502

- 14 1 PIA



# E **G Lever and Support Asm.** 

# 06 06 02

- B0502

- 15 1 0.16 0.16 0.12 **0.44** 0.00 0.03 0.03 0.01 0.07

- $ **0.50**

**$ 0.50** 

**$**

G Pin, Brake Pedal Asm. 

# 06 06 02

- B0502

- 16 1 PIA

G Tinnermann Clip, Pedal Asm. 

# 06 06 02

- B0502

- 17 1 PIA



# F **G Pedal Lever, Asm.** 

# 06 06 02

- B0502

- 18 1 0.26 0.43 1.08 **1.77** 0.01 0.19 0.16 0.05 0.41

- $ **2.19**

**$ 2.19** 

**$**

G Bumper, Brake Pedal 

# 06 06 02

- B0502

- 19 2 PIA

G Bushing, Brake Lever 

# 06 06 02

- B0502

- 20 2 PIA

G Contact Cover, Brake Pedal 

# 06 06 02

- B0502

- 21 1 PIA



# F1 **G Base Pedal Stamping, Asm.** 

# 06 06 02

- B0502

- 22 1 2.49 $ 0.23

$ 1.44

$ **4.16**

**$** 0.02

$ 0.27

$ 0.25

$ 0.10

$ 0.64

$

-

$ **4.80**

**$ 4.80** 

**$**

G Main Stamping, Brake Pedal 

# 06 06 02

- B0502

- 23 1 PIA

G Pedal Contact, Brake Pedal 

# 06 06 02

- B0502

- 24 1 PIA

G Support, Brake Pedal 

# 06 06 02

- B0502

- 25 1 PIA

G Tube, Brake Pedal 

# 06 06 02

- B0502

- 26 1 PIA



# F2 **G Housing, Pedal Asm.** 

# 06 06 02

- B0502

- 27 1 1.12 $ 0.19

$ 1.59

$ **2.91**

**$** 0.01

$ 0.19

$ 0.17

$ 0.07

$ 0.45

$

-

$ **3.36**

**$ 3.36** 

**$**

G Base, Housing, Pedal 

# 06 06 02

- B0502

- 28 1 PIA

G Support, Left, Brake Housing 

# 06 06 02

- B0502

- 29 1 PIA

G Support, Right, Brake Housing 

# 06 06 02

- B0502

- 30 1 PIA

G Brace, Brake Housing 

# 06 06 02

- B0502

- 31 1 PIA



# 5.44 $ 1.84

$ 5.97

$ **13.25**

**$** 0.07

$ 0.95

$ 0.85

$ 0.33

$ **2.20**

**$** 0.10

$ **14.39**

**$ 15.46** 

**$**

**13.25 $**  **2.20 $**  

# Complete Subsystem Quote

(Yes/No) 

# N

**13.25 $**  **2.20 $** 



# NOTES:

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 

# BASE TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

# Notes Manufacturing **Total**

**Manufacturing**

**Cost**

**(Component/**

**Assembly)**SubassemblyComponentSub-Subsystem 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



# Name/Description Part Number Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor

(Default =1) **Net**

**Component/**

**Assembly**

**Cost Impact to**

**OEM System** 

**ED&T/R&D**

**(x1000)** Markup

**Total Markup**

**Cost**

**(Component/**

**Assembly) Total** 

**Packaging**

**Cost**

**(Component**

**/ Assembly)** 

# Technology **Level: Parallel HEV Technology** 

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4** 

**- 6 Passengers** 

**Study Case#:**  **B0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)**

**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**

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



# 06 **02 G Brake Pedal A**  **ssembly 06**  **06 02** 

**- B0502** 

**- 01**  **1**

G Brake Mounting Bracket Asm. 

# 06 06 02

- B0502

- 02 1 Not Mapped - Beyond Scope

G Bolt, Brake Mounting Bracket 

# 06 06 02

- B0502

- 03 2 PIA



# A **G Pedal Box Asm.** 

# 06 06 02

- B0502

- 04 1

G Bolt, Long, Spacer 

# 06 06 02

- B0502

- 05 1 PIA

G Nut, Spacer 

# 06 06 02

- B0502

- 06 1 PIA



# B **G Spacer, Lever and Support Asm.** 

# 06 06 02

- B0502

- 07 1

C **G Bracket, Pedal Stop, Asm.** 

# 06 06 02

- B0502

- 08 1

G Bracket, Pedal Stop 

# 06 06 02

- B0502

- 09 1 PIA

G Tab, Bracket, Pedal Stop 

# 06 06 02

- B0502

- 10 1 PIAQTY/Subsystem 

# NotesSubassemblyComponentSub-Subsystem 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



# Name/Description Part Number Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor

(Default =1) 

# Technology **Level: Parallel HEV Technology** 

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4** 

**- 6 Passengers** 

**Study Case#:**  **B0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)**

**- $** 

**-**

**$ Investment** 

**(X1000) Tooling** 

**(x1000)**

G Tab, Bracket, Pedal Stop 

# 06 06 02

- B0502

- 10 1 PIA

G W eld Nut, Bracket, Stop 

# 06 06 02

- B0502

- 11 1 PIA



# D **G Pedal Stop Asm.** 

# 06 06 02

- B0502

- 12 1

G Bolt, Short, Pedal Stop 

# 06 06 02

- B0502

- 13 1 PIA

G Nut, Pedal Stop 

# 06 06 02

- B0502

- 14 1 PIA



# E **G Lever and Support Asm.** 

# 06 06 02

- B0502

- 15 1

G Pin, Brake Pedal Asm. 

# 06 06 02

- B0502

- 16 1 PIA

G Tinnermann Clip, Pedal Asm. 

# 06 06 02

- B0502

- 17 1 PIA



# F **G Pedal Lever, Asm.** 

# 06 06 02

- B0502

- 18 1

G Bumper, Brake Pedal 

# 06 06 02

- B0502

- 19 2 PIA

G Bushing, Brake Lever 

# 06 06 02

- B0502

- 20 2 PIA

G Contact Cover, Brake Pedal 

# 06 06 02

- B0502

- 21 1 PIA



# F1 **G Base Pedal Stamping, Asm.** 

# 06 06 02

- B0502

- 22 1

G Main Stamping, Brake Pedal 

# 06 06 02

- B0502

- 23 1 PIA

G Pedal Contact, Brake Pedal 

# 06 06 02

- B0502

- 24 1 PIA

G Support, Brake Pedal 

# 06 06 02

- B0502

- 25 1 PIA

G Tube, Brake Pedal 

# 06 06 02

- B0502

- 26 1 PIA



# F2 **G Housing, Pedal Asm.** 

# 06 06 02

- B0502

- 27 1

G Base, Housing, Pedal 

# 06 06 02

- B0502

- 28 1 PIA

G Support, Left, Brake Housing 

# 06 06 02

- B0502

- 29 1 PIA

G Support, Right, Brake Housing 

# 06 06 02

- B0502

- 30 1 PIA

G Brace, Brake Housing 

# 06 06 02

- B0502

- 31 1 PIA



# Complete Subsystem Quote

(Yes/No) 

# N **- $** 

**-**

**$**

**NOTES:**

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

DRAFTQTY/Subsystem 

# NotesSubassemblyComponentSub-Subsystem 

# BASE TECHNOLOGY GENERAL PART INFORMATION:

**2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft**ItemSubsystem 

# BASE TECHNOLOGY PACKAGE QUOTE

**PARAMETERS**Assembly



# Name/Description Part Number Full,

Modification,

Differential,

or Not

Applicable

Quote Level Scaling

Factor

(Default =1) 

# Technology **Level: Parallel HEV Technology** 

**Vehicle Class: Mid to Large Size Passenger Vehicle, 4** 

**- 6 Passengers** 

**Study Case#:**  **B0502 (N=New, B=Base, 05=Technology Package, 02=Vehicle Class)**

**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 Investment** 

**(X1000) Tooling** 

**(x1000)**



# 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 

# 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 (B = Base, 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-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: G Brake Pedal Assembly**  

# Part Number: **060602-B0502-01** 

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



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

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

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

# Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

# Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

# End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

# Material

A 

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

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



# B 

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

1 G Brake Pedal Assembly 060602-B0502-17 **1** Assembly 

# T1 Assembly, Mark-up

Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **114 1**  **2 1**  0.000 **$0.00 $38.55**  **$15.00 $30.00**  **$0.00 $0.34**  **$0.26 $0.60**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.60 $0.60**  **$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**



# 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**



# 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 G Bolt, Brake Mounting Bracket 060602-B0502-03 **1** S **$0.00** $0.08 **$0.00 $0.08**  **$0.08**

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**

**Material**

**$0.08**

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

**Mark-up $0.68** 

**T1 or OEM Total Manufacturing Cost: $0.08**  **$0.34 $0.26**  **$0.68 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.68**

**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**

----- ----- ----- **$0.00 $0.04**  **$0.04 $0.02**  **$0.11** 

# "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

**3 1** 



# Notes:

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

**Base Cost Impact to Vehicle: $0.08**  **$0.34 $0.26**  **$0.68 $0.00**  **$0.04 $0.04**  **$0.02 $0.11**  **$0.79 $0**  **$0**

**Packaging Cost: $0.10** 

**Net Cost Impact to Vehicle: $0.88** 



# 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: 2 of 6 

# 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 (B = Base, 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-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: G Brake Pedal Assembly**  

# Part Number: **060602-B0502-01** 

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



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

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

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

# Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

# Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

# End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

# Material **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: **$0.096 $191,520**  **0.00% 2,250,000**  **60 5.00%**  $240 **798** 72 **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: Option 1, 2 Parts Nest

Part Size: 400x200X300

Parts/Layer: 3x3X2

Number of Layers: 4 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: **$0.096** 

# 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: 3 of 6 

# 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)

**Purchase Part - High Impact Item (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**  

# 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**

G Brake Pedal Assembly 060602-B0502-17



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

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

G Bolt, Brake Mounting Bracket 060602-B0502-03 **$0.34 $0.26**  **$0.60 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Assemble the pedal box assembly to the brake mounting bracket with 2 bolts 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  37.0 2 1 63.0 **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**

**$0.08**

**$0.00**

**$0.00**

**$0.00**

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

**Total**

**$0.34 $0.26**  **$0.68 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$0.68 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: 4 of 6 

# 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: 5 of 6 

# 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)

**Purchase Part - High Impact Item (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!** 

-

G Brake Pedal Assembly 060602-B0502-17



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

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

G Bolt, Brake Mounting Bracket 060602-B0502-03 **114 31.50**  1.00

**#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: 6 of 6 

# 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 6 

# 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 (B = Base, 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-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: G Brake Pedal Assembly**  

# Part Number: **060602-B0502-01** 

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



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

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

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

# Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

# Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

# End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

# Material

A 

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

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



# B 

# Purchase Part - High Impact Item (Full Cost Mapping) **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 G Pedal Box Asm. 060602-B0502-04 **1** Assembly 

# T1 Assembly, Mark-up

Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **114 1**  **2 1**  0.000 **$0.00 $38.55**  **$15.00 $30.00**  **$0.00 $0.34**  **$0.26 $0.60**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.60 $0.60**  **$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**



# 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**



# 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 G Bolt, Long, Spacer 060602-B0502-05 **1** S **$0.00** $0.13 **$0.00 $0.13**  **$0.13**

3 G Nut, Spacer 060602-B0502-06 **1** S **$0.00** $0.03 **$0.00 $0.03**  **$0.03**

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**

**Material**

**$0.16**

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

**Mark-up $0.76** 

**T1 or OEM Total Manufacturing Cost: $0.16**  **$0.34 $0.26**  **$0.76 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.76**

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

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% 

# "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

**3 1** 



# Notes:

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

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

----- ----- ----- **$0.00 $0.05**  **$0.05 $0.02**  **$0.12**

**Base Cost Impact to Vehicle: $0.16**  **$0.34 $0.26**  **$0.76 $0.00**  **$0.05 $0.05**  **$0.02 $0.12**  **$0.88 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $0.88** 



# 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: 2 of 6 

# 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 (B = Base, 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-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: G Brake Pedal Assembly**  

# Part Number: **060602-B0502-01** 

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



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

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

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

# Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

# Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

# End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

# GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES 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 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: 3 of 6 

# 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)

**Purchase Part - High Impact Item (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**  

# 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**

G Pedal Box Asm. 060602-B0502-04



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

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

G Bolt, Long, Spacer 060602-B0502-05

G Nut, Spacer 060602-B0502-06 **$0.34 $0.26**  **$0.60 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Assemble the pedal stop bracket to the lever and support assembly with the spacer and long bolt/nut and

the short screw and nut 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  63.0 1 1 63.0 **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**

**$0.13**

**$0.03**

**$0.00**

**$0.00**

**$0.00**

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

**Total**

**$0.34 $0.26**  **$0.76 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$0.76 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: 4 of 6 

# 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: 5 of 6 

# 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)

**Purchase Part - High Impact Item (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!** 

-

G Pedal Box Asm. 060602-B0502-04



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

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

G Bolt, Long, Spacer 060602-B0502-05

G Nut, Spacer 060602-B0502-06 **114 31.50**  1.00

**#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: 6 of 6 

# 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 6 

# 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 (B = Base, 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-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: G Brake Pedal Assembly**  

# Part Number: **060602-B0502-01** 

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



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

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

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

# Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

# Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

# End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

# Material

A 

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

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



# B 

# Purchase Part - High Impact Item (Full Cost Mapping) **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 G Spacer, Lever and Support Asm 060602-B0502-07 **1** Machine T2/T3 CNC Milling, SSLC 

# LC-Steel-1215, Tubing CNC Operator CNC Turning, SS, BF, DA **3600 1**  **1 1**  0.091 **$0.62 $36.98**  **$20.48 $20.48**  **$0.06 $0.01**  **$0.01 $0.07**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.01**  **$0.08 $0.08**  **$0.06**

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**



# 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**



# 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**

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**

**Material**

**$0.06**

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

**Mark-up $0.08** 

**T1 or OEM Total Manufacturing Cost: $0.06**  **$0.01 $0.01**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.01**  **$0.08**

**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**

----- ----- ----- **$0.00 $0.01**  **$0.00 $0.00**  **$0.01**

**Base Cost Impact to Vehicle: $0.06**  **$0.01 $0.01**  **$0.07 $0.00**  **$0.01 $0.01**  **$0.00 $0.02**  **$0.09 $0**  **$0**

**Packaging Cost: $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

**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: $0.09** 



# 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: 2 of 6 

# 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 (B = Base, 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-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: G Brake Pedal Assembly**  

# Part Number: **060602-B0502-01** 

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



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

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

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

# Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

# Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

# End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

# GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES 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 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: 3 of 6 

# 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)

**Purchase Part - High Impact Item (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**  

# 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**

G Spacer, Lever and Support Asm 060602-B0502-07



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

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.01**  **$0.01 $0.07**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.01** SL-10 auto feed 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  1 1 1 1 **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00**

**$0.00**

**$0.00**

**$0.00**

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

**Total**

**$0.01 $0.01**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.01** 

**$0.08 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: 4 of 6 

# 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: 5 of 6 

# 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)

**Purchase Part - High Impact Item (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!** 

-

G Spacer, Lever and Support Asm 060602-B0502-07



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

**Purchase Part - Commodity ( Value taken from Purchase Part Database) 3600**  **1.00** 1.00

**#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: 6 of 6 

# 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 6 

# 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 (B = Base, 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-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: G Brake Pedal Assembly**  

# Part Number: **060602-B0502-01** 

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



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

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

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

# Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

# Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

# End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

# Material

A 

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

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



# B 

# Purchase Part - High Impact Item (Full Cost Mapping) **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 G Bracket, Pedal Stop Asm 060602-B0502-08 **1** Assembly/Welding 

# T1 Assembly, Mark-up LC-GSteel-1000S, Coil Welding/Soldering Operator Mech. Assembly, LC **171 0.25**  **1 1**  0.000 **$0.48 $41.55**  **$100.00 $100.00**  **$0.00 $0.06**  **$0.58 $0.64**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.64 $0.64**  **$0.00**

2 G Bracket, Pedal Stop

060602-B0502-09 **1** Stamp 

# T1 Assembly, Mark-up

Applied @ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS

**2118 0.5**  **1 1**  0.985 **$0.48 $42.73**  **$42.91 $42.91**  **$0.47 $0.01**  **$0.02 $0.50**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.50 $0.50**  **$0.47**

3 G Tab, Bracket, Pedal Stop

060602-B0502-10 **1** Stamp 

# T1 Assembly, Mark-up

Applied @ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **6000 0.5**  **1 1**  0.130 **$0.48 $42.73**  **$15.50 $15.50**  **$0.06 $0.00**  **$0.00 $0.07**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.07 $0.07**  **$0.06**



# 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**



# 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 G Weld Nut, Bracket, Stop 060602-B0502-11 **1** S **$0.00** $0.02 **$0.00 $0.02**  **$0.02**

3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00**

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

**Material**

**$0.56**

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

**Mark-up $1.24** 

**T1 or OEM Total Manufacturing Cost: $0.56**  **$0.07 $0.61**  **$1.24 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$1.24** 

# "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

**3 1** 



# Notes: **T1 or OEM Total Manufacturing Cost: $0.56**  **$0.07 $0.61**  **$1.24 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$1.24**

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

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

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

----- ----- ----- **$0.01 $0.08**  **$0.07 $0.03**  **$0.19**

**Base Cost Impact to Vehicle: $0.56**  **$0.07 $0.61**  **$1.24 $0.01**  **$0.08 $0.07**  **$0.03 $0.19**  **$1.43 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $1.43**  

# Notes:

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



# Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"

Pallet Options



# File: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 6 

# 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 (B = Base, 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-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: G Brake Pedal Assembly**  

# Part Number: **060602-B0502-01** 

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



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

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

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

# Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

# Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

# End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

# GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES 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 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: 3 of 6 

# 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)

**Purchase Part - High Impact Item (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**  

# 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**

G Bracket, Pedal Stop Asm 060602-B0502-08

G Bracket, Pedal Stop

060602-B0502-09

G Tab, Bracket, Pedal Stop

060602-B0502-10



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

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

G Weld Nut, Bracket, Stop 060602-B0502-11 **$0.06 $0.58**  **$0.64 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Arc weld - brake pedal support, contact and tube to arm 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  21 3 1 21 **1.0 1.0** 

**$0.01 $0.02**  **$0.50 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  200 ton progressive die 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  1.7 1 1 1.7 **1.0 1.0** 

**$0.00 $0.00**  **$0.07 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  25 ton progressive die 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  0.6 1 1 0.6 **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00**

**$0.02**

**$0.00**

**$0.00**

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

**Total**

**$0.07 $0.61**  **$1.24 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$1.24 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: 4 of 6 

# 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: 5 of 6 

# 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)

**Purchase Part - High Impact Item (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!** 

-

G Bracket, Pedal Stop Asm 060602-B0502-08

G Bracket, Pedal Stop

060602-B0502-09

G Tab, Bracket, Pedal Stop

060602-B0502-10



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

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

G Weld Nut, Bracket, Stop 060602-B0502-11 **171 21.00**  0.25

**2118 1.70**  0.50

**6000 0.60**  0.50

**#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: 6 of 6 

# 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 6 

# 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 (B = Base, 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-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: G Brake Pedal Assembly**  

# Part Number: **060602-B0502-01** 

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



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

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

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

# Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

# Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

# End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

# Material

A 

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

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



# B 

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

1 G Pedal Stop Asm. 060602-B0502-12 **1** Assembly 

# T1 Assembly, Mark-up

Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **212 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.09**  **$0.07 $0.16**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.16 $0.16**  **$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**



# 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**



# 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 G Bolt, Short, Pedal Stop 060602-B0502-13 **1** S **$0.00** $0.04 **$0.00 $0.04**  **$0.04**

3 G Nut, Pedal Stop 060602-B0502-14 **1** S **$0.00** $0.03 **$0.00 $0.03**  **$0.03**

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**

**Material**

**$0.07**

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

**Mark-up $0.23** 

**T1 or OEM Total Manufacturing Cost: $0.07**  **$0.09 $0.07**  **$0.23 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.23**

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

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% 

# "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

**3 1** 



# Notes:

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

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

----- ----- ----- **$0.00 $0.02**  **$0.01 $0.01**  **$0.04**

**Base Cost Impact to Vehicle: $0.07**  **$0.09 $0.07**  **$0.23 $0.00**  **$0.02 $0.01**  **$0.01 $0.04**  **$0.27 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $0.27** 



# 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: 2 of 6 

# 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 (B = Base, 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-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: G Brake Pedal Assembly**  

# Part Number: **060602-B0502-01** 

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



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

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

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

# Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

# Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

# End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

# Material **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**



# 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: 3 of 6 

# 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)

**Purchase Part - High Impact Item (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**  

# 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**

G Pedal Stop Asm. 060602-B0502-12



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

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

G Bolt, Short, Pedal Stop 060602-B0502-13

G Nut, Pedal Stop 060602-B0502-14 **$0.09 $0.07**  **$0.16 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Hand start nut to bolt 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  17.0 1 1 17.0 **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00**

**$0.04**

**$0.03**

**$0.00**

**$0.00**

**$0.00**

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

**Total**

**$0.09 $0.07**  **$0.23 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$0.23 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: 4 of 6 

# 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: 5 of 6 

# 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)

**Purchase Part - High Impact Item (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!** 

-

G Pedal Stop Asm. 060602-B0502-12



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

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

G Bolt, Short, Pedal Stop 060602-B0502-13

G Nut, Pedal Stop 060602-B0502-14 **212 17.00**  0.50

**#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: 6 of 6 

# 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 6 

# 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 (B = Base, 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-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: G Brake Pedal Assembly**  

# Part Number: **060602-B0502-01** 

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



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

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

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

# Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

# Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

# End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

# Material

A 

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

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



# B 

# Purchase Part - High Impact Item (Full Cost Mapping) **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 G Lever and Support Asm 060602-B0502-15 **1** Assembly 

# T1 Assembly, Mark-up

Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **124 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.16**  **$0.12 $0.28**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.28 $0.28**  **$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**



# 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**



# 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 G Pin, Brake Pedal Asm. 060602-B0502-16 **1** S **$0.00** $0.15 **$0.00 $0.15**  **$0.15**

3 G Tinnermann Clip, Pedal Asm. 060602-B0502-17 **1** S **$0.00** $0.01 **$0.00 $0.01**  **$0.01**

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**

**Material**

**$0.16**

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

**Mark-up $0.44** 

**T1 or OEM Total Manufacturing Cost: $0.16**  **$0.16 $0.12**  **$0.44 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.44**

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

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% 

# "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

**3 1** 



# Notes:

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

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

----- ----- ----- **$0.00 $0.03**  **$0.03 $0.01**  **$0.07**

**Base Cost Impact to Vehicle: $0.16**  **$0.16 $0.12**  **$0.44 $0.00**  **$0.03 $0.03**  **$0.01 $0.07**  **$0.50 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $0.50** 



# 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: 2 of 6 

# 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 (B = Base, 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-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: G Brake Pedal Assembly**  

# Part Number: **060602-B0502-01** 

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



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

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

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

# Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

# Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

# End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

# GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES 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 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: 3 of 6 

# 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)

**Purchase Part - High Impact Item (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**  

# 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**

G Lever and Support Asm 060602-B0502-15



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

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

G Pin, Brake Pedal Asm. 060602-B0502-16

G Tinnermann Clip, Pedal Asm. 060602-B0502-17 **$0.16 $0.12**  **$0.28 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Assemble Pedal Lever Asm to Housing Pedal Asm with piin and tinnermann clip 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  29.0 3 1 29.0 **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00**

**$0.15**

**$0.01**

**$0.00**

**$0.00**

**$0.00**

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

**Total**

**$0.16 $0.12**  **$0.44 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$0.44 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: 4 of 6 

# 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: 5 of 6 

# 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)

**Purchase Part - High Impact Item (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!** 

-

G Lever and Support Asm 060602-B0502-15



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

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

G Pin, Brake Pedal Asm. 060602-B0502-16

G Tinnermann Clip, Pedal Asm. 060602-B0502-17 **124 29.00**  0.50

**#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: 6 of 6 

# 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 6 

# 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 (B = Base, 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-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: G Brake Pedal Assembly**  

# Part Number: **060602-B0502-01** 

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



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

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

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

# Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

# Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

# End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

# Material

A 

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

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



# B 

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

1 G Pedal Lever Asm 060602-B0502-18 **1** Assembly 

# T1 Assembly, Mark-up

Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **63 0.5**  **1 1**  0.000 **$0.00 $38.55**  **$15.00 $15.00**  **$0.00 $0.31**  **$0.24 $0.55**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.55 $0.55**  **$0.00**

2 G Contact Cover, Brake Pedal 060602-B0502-21 **1** H Contact Cover, Brake Pedal,

SBR ,mold T2/T3 Inject. Mold, SSLC Thermoset-SBR Mold/Cast/Sinter Operator Inject. Mold, LS **182 0.5**  **1 1**  0.178 **$1.32 $41.48**  **$151.77 $151.77**  **$0.23 $0.11**  **$0.83 $1.18**  **0.30% 6.00%**  **4.00% 0.00%**  **10.30% $0.12**  **$1.30 $1.30**  **$0.23**

3 G Bushing, Brake Lever 060602-B0502-20 **2** Vertical Stamping Press,

Tonnage 0-60 

# T1 Assembly, Mark-up

Applied @ Bottom. Copper-Pure, Wire Cut/Punch/Forming Operator Stamp/Form, Terminals **6000 0.5**  **1 1**  0.002 **$2.45 $42.73**  **$15.50 $15.50**  **$0.00 $0.00**  **$0.00 $0.01**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.01 $0.02**  **$0.01**

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**



# 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**



# 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 G Bumper, Brake Pedal 060602-B0502-19 **2** S **$0.00** $0.01 **$0.00 $0.02**  **$0.02**

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**

**Material**

**$0.26**

**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total $1.89**  

# "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

**1** 

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

**Mark-up $1.89** 

**T1 or OEM Total Manufacturing Cost: $0.26**  **$0.43 $1.08**  **$1.77 $0.00**  **$0.07 $0.05**  **$0.00 $0.12**  **$1.89**

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

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

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

----- ----- ----- **$0.01 $0.12**  **$0.11 $0.05**  **$0.29**

**Base Cost Impact to Vehicle: $0.26**  **$0.43 $1.08**  **$1.77 $0.01**  **$0.19 $0.16**  **$0.05 $0.41**  **$2.19 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $2.19**  **3 1** 



# Notes:

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



# Reference Packaging Database for Additonal Infromation

Maximum Pallet Stack Height = 100"



# 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 6 

# 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 (B = Base, 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-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: G Brake Pedal Assembly**  

# Part Number: **060602-B0502-01** 

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



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

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

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

# Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

# Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

# End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

# Material **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 Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

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



# Packaging Cost Total: **$0.000** 

# Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet

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



# File: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 6 

# 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)

**Purchase Part - High Impact Item (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**  

# 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**

G Pedal Lever Asm 060602-B0502-18

G Contact Cover, Brake Pedal 060602-B0502-21

G Bushing, Brake Lever 060602-B0502-20



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

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

G Bumper, Brake Pedal 060602-B0502-19 **$0.31 $0.24**  **$0.55 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Push bumpers in place, press bushings into arm and applt contact cover 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  57.6 4 1 57.6 **1.0 1.0** 

**$0.11 $0.83**  **$1.18 $0.00**  **$0.07 $0.05**  **$0.00 $0.12**  4 Cavity Mold, Box Size 125mm x 17mm 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  19.74 1 4 78.94 **1.0 1.0** 

**$0.01 $0.01**  **$0.02 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  25 ton progressive die 

# 5 **2 10**  **100 47**  **4700 191**  **18.80 85%**  **225 15.98**  0.6 1 1 0.6 **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00**

**$0.02**

**$0.00**

**$0.00**

**$0.00**

**$0.00**

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

**Total**

**$0.43 $1.08**  **$1.77 $0.00**  **$0.07 $0.05**  **$0.00 $0.12** 

**$1.89 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: 4 of 6 

# 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: 5 of 6 

# 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)

**Purchase Part - High Impact Item (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!** 

-

G Pedal Lever Asm 060602-B0502-18

G Contact Cover, Brake Pedal 060602-B0502-21

G Bushing, Brake Lever 060602-B0502-20



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

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

G Bumper, Brake Pedal 060602-B0502-19 **63 57.60**  0.50

**182 19.74**  0.50

**6000 0.60**  0.50

**#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: 6 of 6 

# 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 6 

# 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 (B = Base, 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-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: G Brake Pedal Assembly**  

# Part Number: **060602-B0502-01** 

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



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

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

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

# Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

# Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

# End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

# Material

A 

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

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



# B 

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

2 G Base Pedal, Stamping

060602-B0502-22 **1**

Paint Part 

# T1 Assembly, Mark-up

Applied @ Bottom. Not Applicable General Assembly Mech Assembly, LC, Base **154 0.25**  **3 1**  0.000 **$0.00 $38.55**  **$15.00 $45.00**  **$0.00 $0.06**  **$0.29 $0.35**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.35 $0.35**  **$0.00**

3 G Base Pedal, Stamping

060602-B0502-22A **1** Wash 

# T1 Assembly, Mark-up

Applied @ Bottom. S-Steel-416, Bar General Assembly Washing Equipment, LMC **360 0.25**  **1 1**  0.120 **$1.41 $38.55**  **$20.81 $20.81**  **$0.17 $0.03**  **$0.06 $0.25**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.25 $0.25**  **$0.17**

4 G Base Pedal, Stamping

060602-B0502-22B **1** Welding 

# T1 Assembly, Mark-up

Applied @ Bottom. LC-GSteel-1000S, Coil Welding/Soldering Operator Mech. Assembly, LC **195 0.5**  **2 1**  0.000 **$0.48 $41.55**  **$100.00 $200.00**  **$0.00 $0.11**  **$1.03 $1.13**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.13 $1.13**  **$0.00**

5 G Pedal Contact, Brake Pedal 060602-B0502-24 **1** Vertical Stamping Press,

Tonnage 0-60 

# T1 Assembly, Mark-up

Applied @ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **6000 0.5**  **1 1**  0.398 **$0.48 $42.73**  **$15.50 $15.50**  **$0.19 $0.00**  **$0.00 $0.20**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.20 $0.20**  **$0.19**

6 G Main Stamping, Brake Pedal Arm

060602-B0502-23 **1** Stamp 

# T1 Assembly, Mark-up

Applied @ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SMS

**2000 0.5**  **1 1**  3.990 **$0.48 $42.73**  **$60.65 $60.65**  **$1.92 $0.01**  **$0.03 $1.96**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.96 $1.96**  **$1.92**

7 G Tube, Brake Pedal

060602-B0502-26 **1**

Machine 

# T1 Assembly, Mark-up

Applied @ Bottom. LC-Steel-1215, Tubing CNC Operator CNC Turning, SS, BF, DA **3600 1**  **1 1**  0.104 **$0.62 $36.98**  **$20.48 $20.48**  **$0.06 $0.01**  **$0.01 $0.08**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.08 $0.08**  **$0.06**

8 G Support, Brake Pedal

060602-B0502-25 **1** Stamp 

# T1 Assembly, Mark-up

Applied @ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS

**2000 0.5**  **1 1**  0.309 **$0.48 $42.73**  **$42.91 $42.91**  **$0.15 $0.01**  **$0.02 $0.18**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.18 $0.18**  **$0.15**



# 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**



# 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** 

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

Assembly. 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**

**Material**

**$2.49**

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

**Mark-up $4.16** 

**T1 or OEM Total Manufacturing Cost: $2.49**  **$0.23 $1.44**  **$4.16 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$4.16**

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

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50% 

# Assembly.

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

**3 1** 



# 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: 2 of 6 

# 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 (B = Base, 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-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: G Brake Pedal Assembly**  

# Part Number: **060602-B0502-01** 

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



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

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

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

# Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

# Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

# End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

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

**TOTAL COSTS TOOLING & INVESTMENT**  

# GENERAL COMPONENT INFORMATION **GENERAL MANUFACTURING INFORMATION MANUFACTURING COSTS**  **MANUFACTURING RATES 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)**

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

----- ----- ----- **$0.02 $0.27**  **$0.25 $0.10**  **$0.64**

**Base Cost Impact to Vehicle: $2.49**  **$0.23 $1.44**  **$4.16 $0.02**  **$0.27 $0.25**  **$0.10 $0.64**  **$4.80 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $4.80** 

**Packaging**

**Cost per Total**  **Lump Sum**

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

# PACKAGING CALCULATIONS:

Packaging Type:

Part Size:

Parts/Layer: **Reference Packaging Database for Additonal Infromation**

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years **Cost per**

**Piece Total** 

**Amount 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** 

# Parts/Layer:

Number of Layers: Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm)

Package: 7 Layers of 6 on single Pallet Base.

Cost per Tote: $75/Tote

Cost per Base: 6" Pallet Base, $100/Base

Cardboard Tier Pads for Option 1 Pallets $1.00/Pad (Mike S.)

Cardboard Divider Pads for Option 1 Pallet $3.00/Pad (Mike S.)

ABS Vacuum Form Pads 2.5mm Thick for Option #3 Pallets, $5.00

Returnable Dividers For Option 1 Pallet

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



# File: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 6 

# 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)

**Purchase Part - High Impact Item (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**  

# 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**

G Base Pedal, Stamping

060602-B0502-22

G Base Pedal, Stamping

060602-B0502-22A

G Base Pedal, Stamping

060602-B0502-22B

G Pedal Contact, Brake Pedal 060602-B0502-24

G Main Stamping, Brake Pedal Arm

060602-B0502-23

G Tube, Brake Pedal

060602-B0502-26

G Support, Brake Pedal

060602-B0502-25



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

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.06**  **$0.29 $0.35**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00**

Paint, Paint Oven Cure 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  70 2 1 70 **1.0 3.0** 

**$0.03 $0.06**  **$0.25 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Turbo Tunnel 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  10 1 1 10 **1.0 1.0** 

**$0.11 $1.03**  **$1.13 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  Arc weld - brake pedal support, contact and tube to arm 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  37 5 1 37 **1.0 2.0** 

**$0.00 $0.00**  **$0.20 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  25 ton progressive die 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  0.6 1 1 0.6 **1.0 1.0** 

**$0.01 $0.03**  **$1.96 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  300 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 $0.01**  **$0.08 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  SL-10 auto feed 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  1 1 1 1 **1.0 1.0** 

**$0.01 $0.02**  **$0.18 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  200 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** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00**

**$0.00**

**$0.00**

**$0.00**

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

**Total**

**$0.23 $1.44**  **$4.16 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$4.16 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: 4 of 6 

# 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: 5 of 6 

# 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)

**Purchase Part - High Impact Item (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!** 

-

G Base Pedal, Stamping

060602-B0502-22

G Base Pedal, Stamping

060602-B0502-22A

G Base Pedal, Stamping

060602-B0502-22B

G Pedal Contact, Brake Pedal 060602-B0502-24

G Main Stamping, Brake Pedal Arm

060602-B0502-23

G Tube, Brake Pedal

060602-B0502-26

G Support, Brake Pedal

060602-B0502-25



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

**Purchase Part - Commodity ( Value taken from Purchase Part Database) 154**  **23.33** 0.25

**360 10.00**  0.25

**195 18.50**  0.50

**6000 0.60**  0.50

**2000 1.80**  0.50

**3600 1.00**  1.00

**2000 1.80**  0.50

**#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: 6 of 6 

# 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 6 

# 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 (B = Base, 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-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: G Brake Pedal Assembly**  

# Part Number: **060602-B0502-01** 

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



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

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

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

# Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

# Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

# End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

# Material

A 

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

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



# B 

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

1 G Housing Pedal Asm. 060602-B0502-27 **1** Assembly/Welding 

# T1 Assembly, Mark-up LC-GSteel-1000S, Coil Welding/Soldering Operator Mech. Assembly, LC **131 0.5**  **2 1**  0.000 **$0.48 $41.55**  **$100.00 $200.00**  **$0.00 $0.16**  **$1.53 $1.69**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$1.69 $1.69**  **$0.00**

2 G Base, Housing, Pedal

060602-B0502-28 **1** Stamp 

# T1 Assembly, Mark-up

Applied @ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS

**2118 0.5**  **1 1**  0.505 **$0.48 $42.73**  **$42.91 $42.91**  **$0.24 $0.01**  **$0.02 $0.27**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.27 $0.27**  **$0.24**

3 G Support, Left, Brake Housing

060602-B0502-29 **1** Stamp 

# T1 Assembly, Mark-up

Applied @ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS

**2000 0.5**  **1 1**  0.889 **$0.48 $42.73**  **$42.91 $42.91**  **$0.43 $0.01**  **$0.02 $0.46**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.46 $0.46**  **$0.43**

4 G Support, Right, Brake Housing

060602-B0502-30 **1** Stamp 

# T1 Assembly, Mark-up

Applied @ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, SS

**2118 0.5**  **1 1**  0.737 **$0.48 $42.73**  **$42.91 $42.91**  **$0.35 $0.01**  **$0.02 $0.38**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.38 $0.38**  **$0.35**

5 G Brace, Brake Housing

060602-B0502-31 **1** Stamp 

# T1 Assembly, Mark-up

Applied @ Bottom. LC-GSteel-1000S, Coil Cut/Punch/Forming Operator Stamp/Form, Terminals **6000 0.5**  **1 1**  0.207 **$0.48 $42.73**  **$15.50 $15.50**  **$0.10 $0.00**  **$0.00 $0.11**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$0.11 $0.11**  **$0.10**



# 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**



# 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**

**Material**

**$1.12** 

# "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

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

**Mark-up $2.91** 

**T1 or OEM Total Manufacturing Cost: $1.12**  **$0.19 $1.59**  **$2.91 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$2.91**

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

----- ----- ----- ----- 0.50% 6.50% 6.00% 2.50% 15.50%

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

----- ----- ----- **$0.01 $0.19**  **$0.17 $0.07**  **$0.45**

**Base Cost Impact to Vehicle: $1.12**  **$0.19 $1.59**  **$2.91 $0.01**  **$0.19 $0.17**  **$0.07 $0.45**  **$3.36 $0**  **$0**

**Packaging Cost: $0.00** 

**Net Cost Impact to Vehicle: $3.36**  **3 1** 



# 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: 2 of 6 

# 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 (B = Base, 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-Val. DOHC, NA, PFI, 240hp, 223lb*ft** 

# Annual Component Volume: Shipping Method:

**Component Description: G Brake Pedal Assembly**  

# Part Number: **060602-B0502-01** 

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



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

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

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

# Primary Process

**Description OEM/Supplier** 

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

# Material

**Cost**

**$/lb**

**(DB) Labor** 

**Rate**

**$/Hour**

**(DB) Burden** 

**Rate**

**$/Hour**

**(DB) Applied** 

**Burden**

**Rate**

**$/Hour Material** 

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

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

# End

**Item**

**Scrap**

**Rate**

**(DB) SG&A** 

**Rate**

**(DB) Profit** 

**Rate**

**(DB) ED&T/** 

**R&D**

**Rate**

**(DB) Total** 

**Mark**

**up**

**Rate Total** 

**Mark**

**up**

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

# Material **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 Other #1**  **Other #1 Other #2**  **Other #2 Other #3**  **Other #3** 

# PACKAGING CALCULATIONS:

Packaging Type:

Part Size:

Parts/Layer:

Number of Layers: **Reference Packaging Database for Additonal Infromation**

Maximum Pallet Stack Height = 100"

Pallet Options

Option1: 48"(122cm)x45"(114cm)x34"(86cm)

Investment $200 US funds (Mike S.)

Assume Plastic Returnables Last 5 Years

Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike

S. 020909)

Investment $20K for tool

Piece Price, 6" Pallet Base $100/Base

Piece Price, Tier Pad $40/Pad

**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: 3 of 6 

# 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)

**Purchase Part - High Impact Item (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**  

# 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**

G Housing Pedal Asm. 060602-B0502-27

G Base, Housing, Pedal

060602-B0502-28

G Support, Left, Brake Housing

060602-B0502-29

G Support, Right, Brake Housing

060602-B0502-30

G Brace, Brake Housing

060602-B0502-31



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

**Purchase Part - Commodity ( Value taken from Purchase Part Database) $0.16**  **$1.53 $1.69**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00** Arc weld - brake pedal support, contact and tube to arm 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  55 8 1 55 **1.0 2.0** 

**$0.01 $0.02**  **$0.27 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  200 ton progressive die 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  1.7 1 1 1.7 **1.0 1.0** 

**$0.01 $0.02**  **$0.46 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  300 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**  **$0.38 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  300 ton progressive die 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  1.7 1 1 1.7 **1.0 1.0** 

**$0.00 $0.00**  **$0.11 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  25 ton progressive die 

# 5 **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  0.6 1 1 0.6 **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

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

- - - - **1.0 1.0** 

**$0.00**

**$0.00**

**$0.00**

**$0.00**

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

**Total**

**$0.19 $1.59**  **$2.91 $0.00**  **$0.00 $0.00**  **$0.00 $0.00** 

**$2.91 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: 4 of 6 

# 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: 5 of 6 

# 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)

**Purchase Part - High Impact Item (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!** 

-

G Housing Pedal Asm. 060602-B0502-27

G Base, Housing, Pedal

060602-B0502-28

G Support, Left, Brake Housing

060602-B0502-29

G Support, Right, Brake Housing

060602-B0502-30

G Brace, Brake Housing

060602-B0502-31



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

**Purchase Part - Commodity ( Value taken from Purchase Part Database) 131**  **27.50** 0.50

**2118 1.70**  0.50

**2000 1.80**  0.50

**2118 1.70**  0.50

**6000 0.60**  0.50

**#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: 6 of 6 

# 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

# Indented Bill of Materials

**G Brake Pedal A**

**ssembly**

**Level Sy**  **mbol Name Number** 

**G Pedal Box A**

**sm. G Pedal Box A**  **sm.**

**1 G Lever and Support A**  **sm. G Lever and Support A**  **sm.**

**2 G Pedal Lever, A**  **sm. G Pedal Lever, A**  **sm.**

**3 G Base Pedal Stamping, A**  **sm. G Base Pedal Stamping, A**  **sm.**

**4 G Base Pedal Stamping, A**  **sm., Washed G Base Pedal Stamping, A**  **sm., Washed**

**5 G Base Pedal Stamping, A**  **sm., Welded G Base Pedal Stamping, A**  **sm., Welded**

**6 G Main Stamping, Brake Pedal**  **G Main Stamping, Brake Pedal**

**7** G Main Stamping, Brake Pedal, Raw Material

**6 G Pedal Contact, Brake Pedal**  **G Pedal Contact, Brake Pedal**

**7** G Pedal Contact, Brake Pedal, Raw Material

**6 G Support, Brake Pedal**  **G Support, Brake Pedal**

**7** G Support, Brake Pedal, Raw Material

**6 G Tube, Brake Pedal**  **G Tube, Brake Pedal**

**7** G Tube, Brake Pedal. Raw Material

3 G Bumper, Brake Pedal G Bumper, Brake Pedal

**3 G Bushing, Brake Lever**  **G Bushing, Brake Lever**

**4** G Bushing, Brake Lever, Raw Material G Bushing, Brake Lever, Raw Material

**3 G Contact Cover, Brake Pedal**  **G Contact Cover, Brake Pedal**

**4** G Contact Cover, Brake Pedal, Raw Material G Contact Cover, Brake Pedal, Raw Material

**2 G Housing, Pedal A**  **sm. G Housing, Pedal A**  **sm.**

**3 G Base, Housing, Pedal**  **G Base, Housing, Pedal**

**4** G Base, Housing, Pedal, Raw Material G Base, Housing, Pedal, Raw Material

**3 G Support, Left, Brake Housing**  **G Support, Left, Brake Housing**

**4** G Support, Left, Brake Housing, Raw Material G Support, Left, Brake Housing, Raw Material

**3 G Support, Right, Brake Housing**  **G Support, Right, Brake Housing**

**4** G Support, Right, Brake Housing, Raw Material G Support, Right, Brake Housing, Raw Material

**3 G Brace, Brake Housing**  **G Brace, Brake Housing**

**4** G Brace, Brake Housing, Raw Material G Brace, Brake Housing, Raw Material

2 G Pin, Brake Pedal Asm. G Pin, Brake Pedal Asm.

2 G Tinnermann Clip, Pedal Asm. G Tinnermann Clip, Pedal Asm.

**1 G Spacer, Lever and Support A**  **sm. G Spacer, Lever and Support A**  **sm.**

**2** G Spacer, Lever and Support Asm., Raw Material G Spacer, Lever and Support Asm., Raw Material

1 G Bolt, Long, Spacer G Bolt, Long, Spacer

1 G Nut, Spacer G Nut, Spacer

**1 G Bracket, Pedal Stop, A**  **sm. G Bracket, Pedal Stop, A**  **sm.**

**2 G Bracket, Pedal Stop**  **G Bracket, Pedal Stop1**

**3** G Bracket, Pedal Stop, Raw Material G Bracket, Pedal Stop, Raw Material

**2 G Tab, Bracket, Pedal Stop**  **G Tab, Bracket, Pedal Stop**

**3** G Tab, Bracket, Pedal Stop, Raw Material G Tab, Bracket, Pedal Stop, Raw Material

2 G W eld Nut, Bracket, Stop G W eld Nut, Bracket, Stop

**1 G Pedal Stop A** 

**sm. G Pedal Stop A**  **sm.**

**2** G Bolt, Short, Pedal Stop G Bolt, Short, Pedal Stop

2 G Nut, Pedal Stop G Nut, Pedal Stop

**0 G Brake Mounting Bracket A**  **sm. G Brake Mounting Bracket A**  **sm.**

**0** G Bolt, Brake Mounting Bracket G Bolt, Brake Mounting Bracket



# Assembly Totals

# An **aly zed Subs:** 

23

**Unanaly zed Subs:**  1

**Parts:** 25

**Fasteners:** 8

**Parts+Unanaly**

**zed:** 26

# Design Profit ®

Copyright 2005© Munro & Associates, Inc.

# Qty **Material**



# 1

**G Lever and Support A sm.**  **1**

**G Pedal Lever, A**

**sm. 1** 

**G Base Pedal Stamping, A sm.**  **1**

**G Base Pedal Stamping, A sm., Washed**  **1**

**G Base Pedal Stamping, A sm., Welded**  **1**

**G Main Stamping, Brake Pedal 1**  **Steel - 1018**

G Main Stamping, Brake Pedal, Raw Material **1**

**G Pedal Contact, Brake Pedal 1**  **Steel - 1018**

G Pedal Contact, Brake Pedal, Raw Material **1**

**G Support, Brake Pedal 1**  **Steel - 1018**

G Support, Brake Pedal, Raw Material **1**

**G Tube, Brake Pedal 1**  **Steel - 1018**

G Tube, Brake Pedal. Raw Material **1**

G Bumper, Brake Pedal 2 Commodity Pricing

**G Bushing, Brake Lever 2**  **Copper**

G Bushing, Brake Lever, Raw Material **1** Copper

**G Contact Cover, Brake Pedal 1**  **SBR**

G Contact Cover, Brake Pedal, Raw Material **1** SBR

**G Housing, Pedal A**

**sm. 1** 

**G Base, Housing, Pedal 1**  **Galvinized Steel - G60**

G Base, Housing, Pedal, Raw Material **1** Galvinized Steel - G60

**G Support, Left, Brake Housing 1**  **Galvinized Steel - G60**

G Support, Left, Brake Housing, Raw Material **1** Galvinized Steel - G60

**G Support, Right, Brake Housing 1**  **Galvinized Steel - G60**

G Support, Right, Brake Housing, Raw Material **1** Galvinized Steel - G60

**G Brace, Brake Housing 1**  **Galvinized Steel - G60**

G Brace, Brake Housing, Raw Material **1** Galvinized Steel - G60

G Pin, Brake Pedal Asm. 1 Commodity Pricing

G Tinnermann Clip, Pedal Asm. 1 Commodity Pricing

**G Spacer, Lever and Support A sm.**  **1 Steel - 1008** 

G Spacer, Lever and Support Asm., Raw Material **1** Steel - 1008

G Bolt, Long, Spacer 1 Commodity Pricing

1 Commodity Pricing

**G Bracket, Pedal Stop, A sm.**  **1**

**G Bracket, Pedal Stop1 1**  **Steel - 1018**

G Bracket, Pedal Stop, Raw Material **1** Steel - 1018

**G Tab, Bracket, Pedal Stop 1**  **Steel - 1018**

G Tab, Bracket, Pedal Stop, Raw Material **1** Steel - 1018

G W eld Nut, Bracket, Stop 1 Commodity Pricing

**G Pedal Stop A**

**sm. 1** 

G Bolt, Short, Pedal Stop **1** Commodity Pricing

G Nut, Pedal Stop 1 Commodity Pricing

**G Brake Mounting Bracket A sm.**  **1**

G Bolt, Brake Mounting Bracket **2** Commodity Pricing



# Report Totals

# Piece Cost (Total): $4.81

**Weight (Total):**

6.6327 lb

# Page 1 of 1

# Piece Cost **Weight**



# $4.73 

# 4.3301 lb

**# 3.6221 lb** 

**$2.55 2.3963 lb** 

**$2.31 2.2300 lb** 

**$2.31**

**$2.31**

**Steel - 1018 $1.92** 

Steel - 1018 **$1.92**

**Steel - 1018 $0.19** 

Steel - 1018 **$0.19**

**Steel - 1018 $0.15** 

Steel - 1018 **$0.15**

**Steel - 1018 $0.06** 

Steel - 1018 **$0.06**

Commodity Pricing $0.01

**$0.01 0.0020 lb** 

Copper **$0.01**

**$0.19 0.1557 lb** 

**$0.19**

**$1.12 1.0889 lb** 

**Galvinized Steel - G60 $0.24**  **0.2567 lb**

Galvinized Steel - G60 **$0.24**

**Galvinized Steel - G60 $0.43**  **0.3484 lb**

Galvinized Steel - G60 **$0.43**

**Galvinized Steel - G60 $0.35**  **0.3595 lb**

Galvinized Steel - G60 **$0.35**

**Galvinized Steel - G60 $0.10**  **0.1243 lb**

Galvinized Steel - G60 **$0.10**

Commodity Pricing $0.15 0.1089 lb

Commodity Pricing $0.01 0.0069 lb

**# 0.0895 lb** 

**$0.04 0.0895 lb** 

Commodity Pricing # 0.0634 lb

Commodity Pricing # 0.0130 lb

**# 0.4980 lb** 

**$0.54 0.4113 lb** 

Steel - 1018 **$0.54 0.4113 lb** 

**$0.07 0.0775 lb** 

Steel - 1018 **$0.07 0.0775 lb** 

Commodity Pricing $0.02 0.0092 lb

**# 0.0441 lb** 

Commodity Pricing **$0.04 0.0311 lb** 

Commodity Pricing $0.03 0.0130 lb

**$0.00 2.2500 lb** 

**$0.04 0.0263 lb** 



# Preassembled Totals

# Analyzed Subs: 0

**Unanalyzed Subs:**

0

**Parts:** 0

**Fasteners:**

0

**Parts+Unanalyzed:**

0

# Piece Cost **Weight (Total)**

**(Total)**



# 4.3301 lb **$4.73** 

# 4.3301 lb

**$3.83 3.6221 lb** 

**2.3963 lb $2.55**  **2.3963 lb**

**2.2300 lb $2.31**  **2.2300 lb**

**2.2300 lb $2.31**  **2.2300 lb**

**2.2226 lb $2.31**  **2.2226 lb**

**1.5800 lb $1.92**  **1.5800 lb**

**1.5800 lb $1.92**  **1.5800 lb**

**0.3631 lb $0.19**  **0.3631 lb**

**0.3631 lb $0.19**  **0.3631 lb**

**0.1759 lb $0.15**  **0.1759 lb**

**0.1759 lb $0.15**  **0.1759 lb**

**0.1036 lb $0.06**  **0.1036 lb**

**0.1036 lb $0.06**  **0.1036 lb**

0.0033 lb $0.02 0.0066 lb

**0.0020 lb $0.02**  **0.0040 lb**

**0.0020 lb $0.02**  **0.0040 lb**

**0.1557 lb $0.19**  **0.1557 lb**

**0.1557 lb $0.19**  **0.1557 lb**

**1.0889 lb $1.12**  **1.0889 lb**

**0.2567 lb $0.24**  **0.2567 lb**

**0.2567 lb $0.24**  **0.2567 lb**

**0.3484 lb $0.43**  **0.3484 lb**

**0.3484 lb $0.43**  **0.3484 lb**

**0.3595 lb $0.35**  **0.3595 lb**

**0.3595 lb $0.35**  **0.3595 lb**

**0.1243 lb $0.10**  **0.1243 lb**

**0.1243 lb $0.10**  **0.1243 lb**

0.1089 lb $0.15 0.1089 lb

0.0069 lb $0.01 0.0069 lb

**$0.04 0.0895 lb** 

**0.0895 lb $0.04**  **0.0895 lb**

$0.13 0.0634 lb

$0.03 0.0130 lb

**$0.64 0.4980 lb** 

**0.4113 lb $0.54**  **0.4113 lb**

**0.4113 lb $0.54**  **0.4113 lb**

**0.0775 lb $0.07**  **0.0775 lb**

**0.0775 lb $0.07**  **0.0775 lb**

0.0092 lb $0.02 0.0092 lb

**$0.07 0.0441 lb** 

**0.0311 lb $0.04**  **0.0311 lb**

0.0130 lb $0.03 0.0130 lb

**$0.00 2.2500 lb** 

**$0.08 0.0526 lb** 

# 606 **02 G Brake Pedal A**  **ssembly Part #**  **QTY $$$** 

G Brake Pedal Assembly 1 0.73

G Brake Mounting Bracket Asm. 

# 1

G Bolt, Brake Mounting Bracket 

# 2 0.09



# A **G Pedal Box A sm.**  

# 1 0.75

G Bolt, Long, Spacer 

# 1 0.13

G Nut, Spacer 

# 1 0.03



# B **G Spacer, Lever and Support A sm.**  

# 1 0.09



# C **G Bracket, Pedal Stop, A sm.**  

# 1 0.81

G Bracket, Pedal Stop 

# 1 0.67

G Tab, Bracket, Pedal Stop 

# 1 0.10

G W eld Nut, Bracket, Stop 

# 1 0.02



# D **G Pedal Stop A sm.**  

# 1 0.20

G Bolt, Short, Pedal Stop 

# 1 0.05

G Nut, Pedal Stop 

# 1 0.03



# E **G Lever and Support A sm.**  

# 1 0.34

G Pin, Brake Pedal Asm. 

# 1 0.17

G Tinnermann Clip, Pedal Asm. 

# 1 0.01



# F **G Pedal Lever, A sm.**  

# 1 0.67

G Bumper, Brake Pedal 

# 2 0.02

G Bushing, Brake Lever 

# 2 0.03

G Contact Cover, Brake Pedal 

# 1 1.74



# F1A **G Base Pedal Stamping, A sm.**  

# 1 2.36

G Main Stamping, Brake Pedal 

# 1 2.58

G Pedal Contact, Brake Pedal 

# 1 0.25

G Support, Brake Pedal 

# 1 0.24

G Tube, Brake Pedal 

# 1 0.10



# F1B **G Housing, Pedal A sm.**  

# 1 2.16

G Base, Housing, Pedal 

# 1 0.36

G Support, Left, Brake Housing 

# 1 0.60

G Support, Right, Brake Housing 

# 1 0.51

G Brace, Brake Housing 

# 1 0.14



# 34 15.98

# Comments

Out of scope

Includes, welding, washing & painting

# Shippied into OEM as a Brake Pedal Assembly

Assume Tier 2 shipped as an assembly to T1/OEM

Includes Tier1I/OEM markup Used: **T1 Moderate Assembly Complexity**

Assumed returnable dunnage - no dividers Used: **Returnable Dunnage**