## Page:1 of 16 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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



### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 

# 021100 Electric Motor & Controls Subsy **stem**

1 **00 Assembly of Misc Electric Motor & Controls Subsystem**  **197.55 $**  **115.46**

**$ 193.46** 

**$ 506.47** 

**$ 3.55** 

**$ 35.45** 

**$ 40.52** 

**$ 20.26** 

**$ 99.77** 

**$** 

### 1A Motor - Traction, Electric 02 # 01
- N0502
- 01 1 Full 1 

### 124.78 $ 61.01

$ 101.78

$ **287.57**

**$** 2.01

$ 20.13

$ 23.01

$ 11.50

$ **56.65**

**$** 2A Motor - Generator, Electric 02 # 01
- N0502
- 02 1 Full 1 

### 72.77 $ 54.45

$ 91.68

$ **218.90**

**$** 1.53

$ 15.32

$ 17.51

$ 8.76

$ **43.12**

**$** Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**
MarkupAssembly 

### Name/Description Part NumberQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# 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)

2A Motor - Generator, Electric 02 # 01
- N0502
- 02 1 Full 1 

### 72.77 $ 54.45

$ 91.68

$ **218.90**

**$** 1.53

$ 15.32

$ 17.51

$ 8.76

$ **43.12**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 197.55 $ 115.46

$ 193.46

$ **506.47**

**$** 3.55

$ 35.45

$ 40.52

$ 20.26

$ **99.77**

**$**

**NOTES:** 

## 1. Complete Subsystem Quote (Yes/No) 

## No
**= 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 CONF IDENTIAL Author: G. Kolwich (248)373-6000 Ext. 2411

## Page:2 of 16 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

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

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**
MarkupAssembly 

### Name/Description Part NumberQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# 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)

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

## Page:3 of 16 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

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

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**
MarkupAssembly 

### Name/Description Part NumberQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# 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)

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

## Page:4 of 16 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

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

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**
MarkupAssembly 

### Name/Description Part NumberQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponentSub-Subsystem 

# 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)

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

## Page:5 of 16 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

0 **n/a n/a**  

# 021100 Electric Motor & Controls Subsy **stem**

1 **00 Assembly of Misc Electric Motor & Controls Subsystem** 

1A Motor - Traction, Electric 02 # 01
- N0502
- 01 1 Full 1 

### 2A Motor - Generator, Electric 02 # 01
- N0502
- 02 1 Full 1 

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

Factor (Default =1) 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# 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)

**Scaling Factor Relative to Base**  **(Ford Fusion HEV) Value** 

**- $**  **-**

**$**



### - $ **-**

**$**

- $ **-**

**$**

**0.28 $**  **606.52**

**$ Eliminate one 60kW motor and scale 30kW** 

**motor to P2 motor requirements n/a**  **262.12 $**  

### 0.18 $ **344.40**

**$** 0.10 $ **262.12**

**$** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

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

**Component/ Assembly Cost**  **Impact to OEM Ford Fusion Conversion from e-CVT to**  **IMGA Scaling Parameter Description**  **Ford Fusion Conversion from e-CVT to IMGA** 



### 2A Motor - Generator, Electric 02 # 01
- N0502
- 02 1 Full 1



### NOTES: 

## 1. Complete Subsystem Quote (Yes/No) 

## No
**= 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**  0.10 $ **262.12**

**$**

- $ **-**

**$** 0.28 $ **606.52**

**$**

**-**

**$ 262.12**  **$** Baseline



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

## Page:6 of 16 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

Factor (Default =1) 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# 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)

**Scaling Factor Relative to Base**  **(Ford Fusion HEV) Value** 



# NEW TECHNOLOGY PACKAGE COST INFORMATION

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

**Component/ Assembly Cost**  **Impact to OEM Ford Fusion Conversion from e-CVT to**  **IMGA Scaling Parameter Description**  **Ford Fusion Conversion from e-CVT to IMGA** 



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

## Page:7 of 16 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

Factor (Default =1) 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# 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)

**Scaling Factor Relative to Base**  **(Ford Fusion HEV) Value** 



# NEW TECHNOLOGY PACKAGE COST INFORMATION

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

**Component/ Assembly Cost**  **Impact to OEM Ford Fusion Conversion from e-CVT to**  **IMGA Scaling Parameter Description**  **Ford Fusion Conversion from e-CVT to IMGA** 



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

## Page:8 of 16 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

Factor (Default =1) 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# 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)

**Scaling Factor Relative to Base**  **(Ford Fusion HEV) Value** 



# NEW TECHNOLOGY PACKAGE COST INFORMATION

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

**Component/ Assembly Cost**  **Impact to OEM Ford Fusion Conversion from e-CVT to**  **IMGA Scaling Parameter Description**  **Ford Fusion Conversion from e-CVT to IMGA** 



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

## Page:9 of 16 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

0 **n/a n/a**  

# 021100 Electric Motor & Controls Subsy **stem**

1 **00 Assembly of Misc Electric Motor & Controls Subsystem** 

1A Motor - Traction, Electric 02 # 01
- N0502
- 01 1 Full 1 

### 2A Motor - Generator, Electric 02 # 01
- N0502
- 02 1 Full 1 

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

Factor (Default =1) 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# 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)

**Scaling Factor Relative to Base**  **(Ford Fusion HEV) Value**  **Scaling Factor Relative to Base**  **(Ford Fusion HEV) Value**  **Scaling Factor Relative to Base**  **(Ford Fusion HEV)**

**Extrapolated cost element data from 60kW and 30kW electric motors to develop costs for alternative electric motor sizes. Cost**  **increase/decrease equals $2.74/kW n/a**  **231.95 $**  **n/a 242.92**  **$ n/a**  

# NEW TECHNOLOGY PACKAGE COST INFORMATION

**Scaling Parameter(s) Description Sub-Compact Vehicle Segment**  **Passenger 2-4 (e.g. Ford Fiesta)**  **Small/Compact Vehicle Segment Passenger 2-5**  **(e.g. Ford Focus) Mid Size/Vehicle Segment**  **Passenger 4-6 (e.g. Ford Fusion)** 



### 2A Motor - Generator, Electric 02 # 01
- N0502
- 02 1 Full 1



### NOTES: 

## 1. Complete Subsystem Quote (Yes/No) 

## No
**= 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**  **231.95 $**  **242.92 $**  1 2



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

## Page:10 of 16 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

Factor (Default =1) 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# 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)

**Scaling Factor Relative to Base**  **(Ford Fusion HEV) Value**  **Scaling Factor Relative to Base**  **(Ford Fusion HEV) Value**  **Scaling Factor Relative to Base**  **(Ford Fusion HEV)** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

**Scaling Parameter(s) Description Sub-Compact Vehicle Segment**  **Passenger 2-4 (e.g. Ford Fiesta)**  **Small/Compact Vehicle Segment Passenger 2-5**  **(e.g. Ford Focus) Mid Size/Vehicle Segment**  **Passenger 4-6 (e.g. Ford Fusion)** 



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

## Page:11 of 16 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

Factor (Default =1) 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# 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)

**Scaling Factor Relative to Base**  **(Ford Fusion HEV) Value**  **Scaling Factor Relative to Base**  **(Ford Fusion HEV) Value**  **Scaling Factor Relative to Base**  **(Ford Fusion HEV)** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

**Scaling Parameter(s) Description Sub-Compact Vehicle Segment**  **Passenger 2-4 (e.g. Ford Fiesta)**  **Small/Compact Vehicle Segment Passenger 2-5**  **(e.g. Ford Focus) Mid Size/Vehicle Segment**  **Passenger 4-6 (e.g. Ford Fusion)** 



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

## Page:12 of 16 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

Factor (Default =1) 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# 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)

**Scaling Factor Relative to Base**  **(Ford Fusion HEV) Value**  **Scaling Factor Relative to Base**  **(Ford Fusion HEV) Value**  **Scaling Factor Relative to Base**  **(Ford Fusion HEV)** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

**Scaling Parameter(s) Description Sub-Compact Vehicle Segment**  **Passenger 2-4 (e.g. Ford Fiesta)**  **Small/Compact Vehicle Segment Passenger 2-5**  **(e.g. Ford Focus) Mid Size/Vehicle Segment**  **Passenger 4-6 (e.g. Ford Fusion)** 



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

## Page:13 of 16 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

0 **n/a n/a**  

# 021100 Electric Motor & Controls Subsy **stem**

1 **00 Assembly of Misc Electric Motor & Controls Subsystem** 

1A Motor - Traction, Electric 02 # 01
- N0502
- 01 1 Full 1 

### 2A Motor - Generator, Electric 02 # 01
- N0502
- 02 1 Full 1 

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

Factor (Default =1) 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# 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)

**Value Scaling Factor**  **Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor**  **Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor**  **Relative to Base (Ford Fusion HEV)**  **Value**

**278.58 $**  **n/a 262.12**  **$ n/a**  **253.89 $**  **n/a 273.09**  **$ Passenger + Midsize Towing Truck** 

**Segment Passenger 5-6**  **Towing 4000-5000lbs Passenger or Commercial Truck with**  **Strong Towing Capabilities Passenger 3-6**  **Towing 6000-8000lbs Mid Size/Vehicle Segment**  **Passenger 4-6 (e.g. Ford Fusion)**  **Large Size Vehicle Segment Passenger 6-8**  **(e.g. Ford Flex)**



### 2A Motor - Generator, Electric 02 # 01
- N0502
- 02 1 Full 1



### NOTES: 

## 1. Complete Subsystem Quote (Yes/No) 

## No
**= 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**  **278.58 $**  **262.12 $**  **253.89 $**  **273.09 $**  3 4 5 6



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

## Page:14 of 16 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

Factor (Default =1) 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# 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)

**Value Scaling Factor**  **Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor**  **Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor**  **Relative to Base (Ford Fusion HEV)**  **Value Passenger + Midsize Towing Truck** 

**Segment Passenger 5-6**  **Towing 4000-5000lbs Passenger or Commercial Truck with**  **Strong Towing Capabilities Passenger 3-6**  **Towing 6000-8000lbs Mid Size/Vehicle Segment**  **Passenger 4-6 (e.g. Ford Fusion)**  **Large Size Vehicle Segment Passenger 6-8**  **(e.g. Ford Flex)**



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

## Page:15 of 16 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

Factor (Default =1) 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# 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)

**Value Scaling Factor**  **Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor**  **Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor**  **Relative to Base (Ford Fusion HEV)**  **Value Passenger + Midsize Towing Truck** 

**Segment Passenger 5-6**  **Towing 4000-5000lbs Passenger or Commercial Truck with**  **Strong Towing Capabilities Passenger 3-6**  **Towing 6000-8000lbs Mid Size/Vehicle Segment**  **Passenger 4-6 (e.g. Ford Fusion)**  **Large Size Vehicle Segment Passenger 6-8**  **(e.g. Ford Flex)**



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

## Page:16 of 16 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

Factor (Default =1) 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS**Assembly 

### Name/Description Part NumberQTY/Subsystem 

### NotesSubassemblyComponentSub-Subsystem 

# 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)

**Value Scaling Factor**  **Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor**  **Relative to Base (Ford Fusion HEV)**  **Value Scaling Factor**  **Relative to Base (Ford Fusion HEV)**  **Value Passenger + Midsize Towing Truck** 

**Segment Passenger 5-6**  **Towing 4000-5000lbs Passenger or Commercial Truck with**  **Strong Towing Capabilities Passenger 3-6**  **Towing 6000-8000lbs Mid Size/Vehicle Segment**  **Passenger 4-6 (e.g. Ford Fusion)**  **Large Size Vehicle Segment Passenger 6-8**  **(e.g. Ford Flex)**



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

## Page:1 of 10 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

Material Labor Burden End Item Scrap SG&A Profit ED&TR&D Material Labor Burden 

# 021100 Electric Motor & Controls Subsy **stem** 1 **00 Assembly of Misc Electric Motor & Controls Subsystem**  **197.55 $**  **115.46**

**$ 193.46** 

**$ 506.47** 

**$ 3.55** 

**$ 35.45** 

**$ 40.52** 

**$ 20.26** 

**$ 99.77** 

**$ 0.28** 

**$ 606.52** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 2 **01 Traction and Generator Motors**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 3 **02 Power Electronic Components and Assemblies**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 4 **03 Control Modules**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 5 **04 Traction and Generator Motor Sensors**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly)** 

### Sub-Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTION **NEW TECHNOLOGY GENERAL PART INFORMATION: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net),**  **(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly) Tooling**  **(x1000)** Markup **Net Component/**  **Assembly Cost Impact**  **to OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)** ItemSubsystem **System ED&T/R&D**  **(x1000) Investment**  **(X1000)** 

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

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

6 **05 Internal Electrical Connections (e.g.wire harness, terminals, bus bars)**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 7 **10 Plugs**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 8 **15 Switches**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 9 **72 Electrical Housings/Support Structure**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 10 **75 Brackets**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 11 **80 Boltings**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 12 **85 Sealing Elements**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 13 **90 Bearing Elements**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 14 **91 Shims**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 15 **99 Miscellaneous**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ $**  **$ $**  **$ $**  **$ $**  **$ $**  **$ $**  **$ $**  **$ $**  **$ $** 



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

## Page:2 of 10 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

Material Labor Burden End Item Scrap SG&A Profit ED&TR&D Material Labor Burden 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly)** 

### Sub-Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTION **NEW TECHNOLOGY GENERAL PART INFORMATION: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net),**  **(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly) Tooling**  **(x1000)** Markup **Net Component/**  **Assembly Cost Impact**  **to OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)** ItemSubsystem **System ED&T/R&D**  **(x1000) Investment**  **(X1000)** 

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

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

**197.55 $**  **115.46**

**$ 193.46** 

**$ 506.47** 

**$ 3.55** 

**$ 35.45** 

**$ 40.52** 

**$ 20.26** 

**$ 99.77** 

**$ 0.28** 

**$ 606.52** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### -

**$ -** 

**$ -** 

**$ -** 

**$ SUBSYSTEM ROLL-UP** 



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

## Page:3 of 10 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

Material Labor Burden End Item Scrap SG&A Profit ED&TR&D Material Labor Burden 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly)** 

### Sub-Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTION **NEW TECHNOLOGY GENERAL PART INFORMATION: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net),**  **(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly) Tooling**  **(x1000)** Markup **Net Component/**  **Assembly Cost Impact**  **to OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)** ItemSubsystem **System ED&T/R&D**  **(x1000) Investment**  **(X1000)** 

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

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



# BASE

Material Labor Burden End Item Scrap SG&A Profit ED&TR&D Material Labor Burden 

# 05 **Cy linder Blocks**  A1 **01**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** B1 **02**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** C1 **03**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** D1 **04** #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**
- $
-

$
-

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

### 2 #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF! -**  **$ -** 

**$ -** 

**$** 

### #REF! #REF! #REF! **#REF!** E1 **65**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** F1 **66**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** G1 **67**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** H1 **70**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** I1 **75**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$ System**  **ED&T/R&D (x1000)**  **Tooling**

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY PACKAGE COST INFORMATION
Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly) Total Markup**  **Cost (Component/**  **Assembly) Total** 

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

**Component/ Assembly**  **Cost Impact to OEM**  Markup 

# BASE **TECHNO LOGY**  Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly)** 

# BASE TECHNOLOGY PACKAGE COST INFORMATIONItemSubsystemSub-Subsystem



### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** J1 **80**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$**



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

## Page:4 of 10 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

Material Labor Burden End Item Scrap SG&A Profit ED&TR&D Material Labor Burden 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly)** 

### Sub-Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTION **NEW TECHNOLOGY GENERAL PART INFORMATION: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net),**  **(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly) Tooling**  **(x1000)** Markup **Net Component/**  **Assembly Cost Impact**  **to OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)** ItemSubsystem **System ED&T/R&D**  **(x1000) Investment**  **(X1000)** 

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

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

2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** K1 **85**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** L1 **90**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** M1 **99**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** N1 **00**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### 2
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$ SU**  **BS YS**  #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF! -**  **$ -** 

**$ -** 

**$** 

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

# TECHNO

Material Labor Burden End Item Scrap SG&A Profit ED&TR&D Material Labor Burden 

# 05 **Cy linder Blocks**  A1 **01** 197.55 $ 115.46

$ 193.46

$ **506.47**

**$** 3.55

$ 35.45

$ 40.52

$ 20.26

$ **99.77**

**$** 0.28

$ **606.52**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### B1 **02**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### C1 **03**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### D1 **04** #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF!**
- $
-

$
-

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

### E1 **65**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### F1 **66**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### G1 **67**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### H1 **70**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### I1 **75**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$ System**  **ED&T/R&D (x1000)**  **Tooling**

**(x1000) Investment** 

**(X1000)** 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly)** 

# TECHNO **LOGY PACKAG**  **INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE**ItemSubsystemSub-Subsystem Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM** 



### J1 **80**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$**



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

## Page:5 of 10 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

Material Labor Burden End Item Scrap SG&A Profit ED&TR&D Material Labor Burden 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly)** 

### Sub-Subsystem Description 

# SYSTEM & SUBSYSTEM DESCRIPTION **NEW TECHNOLOGY GENERAL PART INFORMATION: 2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net),**  **(Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly) Tooling**  **(x1000)** Markup **Net Component/**  **Assembly Cost Impact**  **to OEM Total Markup**  **Cost (Component/**  **Assembly) Total** 

**Packaging Cost**  **(Component / Assembly)** ItemSubsystem **System ED&T/R&D**  **(x1000) Investment**  **(X1000)** 

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

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

K1 **85**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### L1 **90**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### -

$
-

$
-

$ **-**

**$** M1 **99**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### N1 **00**
- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$
-

$
-

$
-

$ **-**

**$** 

### SU **BS YS**  #REF! #REF! #REF! **#REF!** #REF! #REF! #REF! #REF! **#REF!** #REF! **#REF! -**  **$ -** 

**$ -** 

**$** 

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



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

## Page:6 of 10 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT



# 021100 Electric Motor & Controls Subsy **stem** 1 **00** 2 **01** 3 **02** 4 **03** 5 **04** 

# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem End Item Scrap SG&A Profit ED&TR&D Material Labor Burden End Item Scrap SG&A Profit ED&TR&D

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ 197.55** 

**$ 115.46** 

**$ 193.46** 

**$ 506.47** 

**$ 3.55** 

**$ 35.45** 

**$ 40.52** 

**$ 20.26** 

**$ 99.77** 

**$ 0.28** 

**$ 606.52** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ System**  **ED&T/R&D (x1000)**  **Tooling**

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

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  **Investment(X1 000)** 



### 6 **05** 7 **10** 8 **15** 9 **72** 10 **75** 11 **80** 12 **85** 13 **90** 14 **91** 15 **99** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a** 0 **n/a -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

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



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

## Page:7 of 10 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem End Item Scrap SG&A Profit ED&TR&D Material Labor Burden End Item Scrap SG&A Profit ED&TR&D **System ED&T/R&D**  **(x1000) Tooling** 

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

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  **Investment(X1 000)** 



### - **$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$** 

### ###### **115.46 $**  **193.46**

**$ 506.47** 

**$ 3.55** 

**$ 35.45** 

**$ 40.52** 

**$ 20.26** 

**$ 99.77** 

**$ 0.28** 

**$ 606.52** 

**$ -** 

**$ -** 

**$ -** 

**$**



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

## Page:8 of 10 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



# BASE End Item

Scrap SG&A Profit ED&TR&D Material Labor Burden End Item Scrap SG&A Profit ED&TR&D **System ED&T/R&D**  **(x1000) Tooling** 

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

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  **Investment(X1 000)** 



# 05 **Cy linder Blocks**  A1 **01** 2 B1 **02** 2 C1 **03** 2 D1 **04** 2 E1 **65** 2 F1 **66** 2 G1 **67** 2 H1 **70** 2 I1 **75** 

# BASE **TECHNO LOGY** ItemSubsystemSub-Subsystem
End Item

Scrap SG&A Profit ED&TR&D

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

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

$
-

$ 

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

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$ **Tooling (x1000)**  Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  **System**

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

# BASE TECHNOLOGY PACKAGE COST INFORMATION

**Investment (X1000)** 



### 2 J1 **80** -

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



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

## Page:9 of 10 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### 2 K1 **85** 2 L1 **90** 2 M1 **99** 2 N1 **00** 2 **SU**

**BS YS**  

# TECHNO End Item

Scrap SG&A Profit ED&TR&D Material Labor Burden End Item Scrap SG&A Profit ED&TR&D **System ED&T/R&D**  **(x1000) Tooling** 

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

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  **Investment(X1 000)** 



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

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

**$ -** 

**$**



# 05 **Cy linder Blocks**  A1 **01** B1 **02** C1 **03** D1 **04** E1 **65** F1 **66** G1 **67** H1 **70** I1 **75** 

# TECHNO **LOGY PACKAG** ItemSubsystemSub-Subsystem
End Item

Scrap SG&A Profit ED&TR&D

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

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

$
-

$

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$ 

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  **System**

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



### J1 **80**
-

$
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



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

## Page:10 of 10 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT



# SYSTEM & SUBSYSTEM DESCRIPTIONItemSubsystem



### K1 **85** L1 **90** M1 **99** N1 **00**

**SU BS**  **YS** End Item Scrap SG&A Profit ED&TR&D Material Labor Burden End Item Scrap SG&A Profit ED&TR&D **System ED&T/R&D**  **(x1000) Tooling** 

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

**(x1000) Investment** 

**(X1000)** 

# BASE TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 3.0L V6, 4-Val. DOHC, NA, PFI, 240hp, 223lb*ft** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  

# INCREMENTAL COST TO UPGRADE TO NEW TECHNOLOGY PACKAGE
Manufacturing **Total Manufacturin**  **g Cost (Component/**  **Assembly)** Markup **Total Markup Cost**  **(Component/ Assembly)**  **Total**

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

**Component/ Assembly**  **Cost Impact to OEM**  **Investment(X1 000)** 

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$



### - $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$

- $
-

$
-

$
-

$ **-**

**$**
-

$ **-**

**$**
-

$
-

$
-

$


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

**$ -** 

**$**



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

## Page:1 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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



### 0 **n/a n/a**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 

# 021100 Electric Motor & Controls Subsy **stem** 1 **00 Assembly of Misc Electric Motor & Controls Subsystem**  **197.55 $**  **115.46**

**$ 193.46** 

**$ 506.47** 

**$ 3.55** 

**$ 35.45** 

**$ 40.52** 

**$ 20.26** 

**$ 99.77** 

**$** 

### 1A Motor - Traction, Electric 02 # 01
- N0502
- 01 1 Full 1 

### 124.78 $ 61.01

$ 101.78

$ **287.57**

**$** 2.01

$ 20.13

$ 23.01

$ 11.50

$ **56.65**

**$** 2A Motor - Generator, Electric 02 # 01
- N0502
- 02 1 Full 1 

### 72.77 $ 54.45

$ 91.68

$ **218.90**

**$** 1.53

$ 15.32

$ 17.51

$ 8.76

$ **43.12**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**Sub-Subsystem 

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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 Traction and Generator Motors**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** $ $ $ **$** $ $ $ $ **$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**



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

## Page:2 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 3 **02 Power Electronic Components and Assemblies**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** $ $ $ **$** $ $ $ $ **$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**


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

## Page:3 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 4 **03 Control Modules**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** $ $ $ **$** $ $ $ $ **$** 5 **04 Traction and Generator Motor Sensors**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**


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

## Page:4 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# Technology **Level:** Power
- Split HEV Technology **Vehicle Class:** Mid to Large Size Passenger Vehicle, 4
- 6 Passengers 

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

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 6 **05 Internal Electrical Connections (e.g.wire harness, terminals, bus bars)**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** $ $ $ **$** $ $ $ $ **$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**


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

## Page:5 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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 Plugs**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** $ $ $ **$** $ $ $ $ **$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**


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

## Page:6 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 8 **15 Switches**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 9 **72 Electrical Housings/Support Structure**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** $ $ $ **$** $ $ $ $ **$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**


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

## Page:7 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 10 **75 Brackets**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** $ $ $ **$** $ $ $ $ **$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**


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

## Page:8 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 11 **80 Boltings**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 12 **85 Sealing Elements**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** $ $ $ **$** $ $ $ $ **$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**


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

## Page:9 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 13 **90 Bearing Elements**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** $ $ $ **$** $ $ $ $ **$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**


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

## Page:10 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 14 **91 Shims**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** $ $ $ **$** $ $ $ $ **$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**


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

## Page:11 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)

15 **99 Miscellaneous**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**

- $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 16 **na na**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 17 **na na**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$** 18 **na na**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$ -** 

**$**



### - $
-

$
-

$ **-**

**$**
-

$
-

$
-

$
-

$ **-**

**$**
197.55 $ 115.46

$ 193.46

$ **506.47**

**$** 3.55

$ 35.45

$ 40.52

$ 20.26

$ **99.77**

**$** Complete Subsystem Quote 

## No

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

## Page:12 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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

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

## Page:13 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

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

### Part Number 

# NEW TECHNOLOGY PACKAGE COST INFORMATIONQTY/Subsystem 

### Notes Manufacturing **Total Manufacturing**  **Cost (Component/**  **Assembly)**SubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW TECHNOLOGY PACKAGE QUOTE **PARAMETERS** MarkupAssembly 

### Name/Description Full, Modification, Differential, or Not Applicable Quote Level Scaling

Factor (Default =1) **Total Markup Cost**  **(Component/ Assembly)**  

# 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)

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

## Page:14 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFT

0 **n/a n/a**  

# 021100 Electric Motor & Controls Subsy **stem** 1 **00 Assembly of Misc Electric Motor & Controls Subsystem** 

1A Motor - Traction, Electric 02 # 01
- N0502
- 01 1 Full 1 

### 2A Motor - Generator, Electric 02 # 01
- N0502
- 02 1 Full 1Sub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW 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)

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**0.28 $**  **606.52**

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0.18 $ **344.40**

**$ -** 

**$ -** 

**$ -** 

**$** 

### 0.10 $ **262.12**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

**System ED&T/R&D**  **(x1000) Investment**  **(X1000) Tooling (x1000)**  **Total Packaging Cost**  **(Component/ Assembly)**  **Net**

**Component/ Assembly Cost**  **Impact to OEM**



### 2 **01 Traction and Generator Motors**  - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$ $**  **$ $** 



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



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

## Page:15 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW 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)


# NEW TECHNOLOGY PACKAGE COST INFORMATION

**System ED&T/R&D**  **(x1000) Investment**  **(X1000) Tooling (x1000)**  **Total Packaging Cost**  **(Component/ Assembly)**  **Net**

**Component/ Assembly Cost**  **Impact to OEM**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### 3 **02 Power Electronic Components and Assemblies**  - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$ $**  **$ $** 



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


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

## Page:16 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW 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)

4 **03 Control Modules**  

# NEW TECHNOLOGY PACKAGE COST INFORMATION

**System ED&T/R&D**  **(x1000) Investment**  **(X1000) Tooling (x1000)**  **Total Packaging Cost**  **(Component/ Assembly)**  **Net**

**Component/ Assembly Cost**  **Impact to OEM**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### 5 **04 Traction and Generator Motor Sensors**  - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**


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

## Page:17 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW 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)


# NEW TECHNOLOGY PACKAGE COST INFORMATION

**System ED&T/R&D**  **(x1000) Investment**  **(X1000) Tooling (x1000)**  **Total Packaging Cost**  **(Component/ Assembly)**  **Net**

**Component/ Assembly Cost**  **Impact to OEM**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### 6 **05 Internal Electrical Connections (e.g.wire harness, terminals, bus bars)**  - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$ $**  **$ $** 



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


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

## Page:18 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW 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)


# NEW TECHNOLOGY PACKAGE COST INFORMATION

**System ED&T/R&D**  **(x1000) Investment**  **(X1000) Tooling (x1000)**  **Total Packaging Cost**  **(Component/ Assembly)**  **Net**

**Component/ Assembly Cost**  **Impact to OEM**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### 7 **10 Plugs**  - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$ $**  **$ $** 



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


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

## Page:19 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW 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)

8 **15 Switches**  

# NEW TECHNOLOGY PACKAGE COST INFORMATION

**System ED&T/R&D**  **(x1000) Investment**  **(X1000) Tooling (x1000)**  **Total Packaging Cost**  **(Component/ Assembly)**  **Net**

**Component/ Assembly Cost**  **Impact to OEM**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### 9 **72 Electrical Housings/Support Structure**  - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$ $**  **$ $** 



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


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

## Page:20 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW 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)


# NEW TECHNOLOGY PACKAGE COST INFORMATION

**System ED&T/R&D**  **(x1000) Investment**  **(X1000) Tooling (x1000)**  **Total Packaging Cost**  **(Component/ Assembly)**  **Net**

**Component/ Assembly Cost**  **Impact to OEM**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### 10 **75 Brackets**  - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$ $**  **$ $** 



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


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

## Page:21 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW 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)

11 **80 Boltings**  

# NEW TECHNOLOGY PACKAGE COST INFORMATION

**System ED&T/R&D**  **(x1000) Investment**  **(X1000) Tooling (x1000)**  **Total Packaging Cost**  **(Component/ Assembly)**  **Net**

**Component/ Assembly Cost**  **Impact to OEM**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### 12 **85 Sealing Elements**  - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$ $**  **$ $** 



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


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

## Page:22 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW 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)


# NEW TECHNOLOGY PACKAGE COST INFORMATION

**System ED&T/R&D**  **(x1000) Investment**  **(X1000) Tooling (x1000)**  **Total Packaging Cost**  **(Component/ Assembly)**  **Net**

**Component/ Assembly Cost**  **Impact to OEM**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### 13 **90 Bearing Elements**  - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$ $**  **$ $** 



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


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

## Page:23 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW 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)


# NEW TECHNOLOGY PACKAGE COST INFORMATION

**System ED&T/R&D**  **(x1000) Investment**  **(X1000) Tooling (x1000)**  **Total Packaging Cost**  **(Component/ Assembly)**  **Net**

**Component/ Assembly Cost**  **Impact to OEM**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### 14 **91 Shims**  **- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$** 

### $ **$ $**  **$ $** 



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


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

## Page:24 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW 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)

15 **99 Miscellaneous**  

# NEW TECHNOLOGY PACKAGE COST INFORMATION

**System ED&T/R&D**  **(x1000) Investment**  **(X1000) Tooling (x1000)**  **Total Packaging Cost**  **(Component/ Assembly)**  **Net**

**Component/ Assembly Cost**  **Impact to OEM**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### 16 **na na** 
17 **na na** 
18 **na na**  - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**

**- $**  **-**

**$ -** 

**$ -** 

**$ -** 

**$**



### - $ **-**

**$ -** 

**$ -** 

**$ -** 

**$**


### Complete Subsystem Quote 

## No 0.28 $ **606.52**

**$ -** 

**$ -** 

**$ -** 

**$**



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

## Page:25 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW 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 

# NEW TECHNOLOGY PACKAGE COST INFORMATION

**System ED&T/R&D**  **(x1000) Investment**  **(X1000) Tooling (x1000)**  **Total Packaging Cost**  **(Component/ Assembly)**  **Net**

**Component/ Assembly Cost**  **Impact to OEM**



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

## Page:26 of 26 

# COST MODEL ANALYSIS TEMPLATE **Light-Duty Technology Cost Study EP-C-07-069 WA1-3**  Printed: 8/30/2012 DRAFTSub-Subsystem 

### Part NumberQTY/Subsystem 

### NotesSubassemblyComponent 

# NEW TECHNOLOGY GENERAL PART INFORMATION: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), (Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** ItemSubsystem 

# NEW 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)


# NEW TECHNOLOGY PACKAGE COST INFORMATION

**System ED&T/R&D**  **(x1000) Investment**  **(X1000) Tooling (x1000)**  **Total Packaging Cost**  **(Component/ Assembly)**  **Net**

**Component/ Assembly Cost**  **Impact to OEM**



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

## Page: 1 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 DRAFT **Technology Level:** OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

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

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

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: Motor - Traction, Electric**  

## Part Number: **021101-N0502-01** 

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

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

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

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

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

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

### End

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

### Material **Labor**

A 

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

1 1A Traction Motor 021101-N0502-01 **1 #####**  **0 1**  **1** 0.000 **$0.00 $0.00**  **$0.00 $0.00**  **$124.78 $61.01**  **$101.78 $287.57**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$287.57 $287.57**  **$124.78 $61.01** 
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 $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 $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 $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 $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 $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 $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 $0.00**  

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

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

**MARK-UP COSTS Manufacturing Costs x Quantity**  **9,574 10**  **North America North America**  **FOB Ship Point 47**  **450,000 1**  **450,000** 1. Everything is based on sequential operations in Lean Design how do we account for multiple machines, people etc.



## Cost Developed Using Surrogate Motor Approach **Ful l Quo**  **te** 

### Modification Quote **Differential Quote (Quote S um**  **mary in clu**  **des costing for both T echnology Packages)** 

8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $0.00**  30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $0.00** 



## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 2 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 DRAFT **Technology Level:** OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

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

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

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: Motor - Traction, Electric**  

## Part Number: **021101-N0502-01** 

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

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

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

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

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

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

### End

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

### Material **Labor 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 Quo**  **te** 

### Modification Quote **Differential Quote (Quote S um**  **mary in clu**  **des costing for both T echnology Packages)** 

18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $0.00**  30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $0.00**  30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $0.00** 


### D 

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

**Price/ Unit**  **Purchase Price Net,**  **PIA Purchase** 

**Price Net, End Item**  1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 2 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 5 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### "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 

## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 3 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 DRAFT **Technology Level:** OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

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

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

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: Motor - Traction, Electric**  

## Part Number: **021101-N0502-01** 

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

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

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

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

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

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

### End

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

### Material **Labor 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 Quo**  **te** 

### Modification Quote **Differential Quote (Quote S um**  **mary in clu**  **des costing for both T echnology Packages)** 

6 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 7 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 10 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 11 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 12 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### accounted for in T1 quote sheet. Thus component cost will only be included for Mark
- up Calculations. "Alpha
- Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 21 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 22 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 23 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 24 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 25 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 26 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 27 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 28 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 29 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 30 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00 Material**  **Labor $124.78**  **$61.01**
**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$287.57 T1 or OEM Total Manufacturing Cost:**  **$124.78 $61.01**  **$101.78 $287.57**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $287.57** 

**T1 or OEM Mark-Up Rates:**
----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70% **(SAC) &T1 or OEM Mark-Up Values:**  **0.00**
----- ----- ----- **$2.01 $20.13**  **$23.01 $11.50**  **$56.65 Base Cost Impact to Vehicle:**  **$124.78 $61.01**  **$101.78 $287.57**  **$2.01 $20.13**  **$23.01 $11.50**  **$56.65 $344.22**  **$0 $0**  **Packaging Cost: $0.18**  **Net Cost Impact to Vehicle: $344.40** **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** **/ N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **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: Option 1 **3 1**  

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



### Reference Packaging Database for Additional Information Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) **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:**  **$0.180 $360,000**  **0.00% 2,250,000**  **60 5.00%**  $1,000 **360** 160 **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: $0.180**  

### Packaging Type: Option 1 Part Size: OD 236 x 95 Height Parts/Layer: 5X4 Number of Layers: 8 Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.) Assume Plastic Returnable Last 5 Years Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base 

## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 4 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 DRAFT **Technology Level:** OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

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

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

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: Motor - Traction, Electric**  

## Part Number: **021101-N0502-01** 

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

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

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

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

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

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

### End

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

### Material **Labor 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 Quo**  **te** 

### Modification Quote **Differential Quote (Quote S um**  **mary in clu**  **des costing for both T echnology Packages)** 



### 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



## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 5 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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 Traction Motor 021101-N0502-01



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



### 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 k** **t 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 R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r**

**$101.78 $287.57**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 5**  **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  - - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0!** 

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



## Purchase Part - High Impact Item (Full Cost Mapping) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 5**  **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0!**

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

## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 6 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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.



### 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 k** **t 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 R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r** 

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

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

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


## Purchase Part - Commodity ( Value taken from Purchase Part Database) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 5**  **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0!**

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

## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 7 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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.



### 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 k** **t 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 R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r** 

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

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up**  **Total $101.78**  **$287.57 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$287.57 2** 

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



## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 8 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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.



### 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 k** **t 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 R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r** 

### 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**



## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 9 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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 Traction Motor 021101-N0502-01



### 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 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!**
-



## 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!**
- 

## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 10 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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 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!**
- 

## 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!**
-


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



## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 11 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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 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** 



## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 12 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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 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** 



## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 1 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 DRAFT **Technology Level:** OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

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

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

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: Motor - Generator, Electric**  

## Part Number: **021101-N0502-02** 

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

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

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

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

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

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

### End

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

### Material **Labor**

A 

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

1 1A Motor - Generator, Electric 021101-N0502-02 **1 #####**  **0 1**  **1** 0.000 **$0.00 $0.00**  **$0.00 $0.00**  **$72.77 $54.45**  **$91.68 $218.90**  **0.00% 0.00%**  **0.00% 0.00%**  **0.00% $0.00**  **$218.90 $218.90**  **$72.77 $54.45** 
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 $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 $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 $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 $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 $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 $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 $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.



## Cost Developed Using Surrogate Motor Approach **Ful l Quo**  **te** 

### Modification Quote **Differential Quote (Quote S um**  **mary in clu**  **des costing for both T echnology Packages)** 

8 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $0.00**  30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $0.00** 



## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 2 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 DRAFT **Technology Level:** OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

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

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

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: Motor - Generator, Electric**  

## Part Number: **021101-N0502-02** 

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

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

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

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

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

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

### End

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

### Material **Labor 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 Quo**  **te** 

### Modification Quote **Differential Quote (Quote S um**  **mary in clu**  **des costing for both T echnology Packages)** 

18 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $0.00**  30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $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 $0.00**  30 **0 #####**  **0 1**  **1** 0.000 **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A #N/A**  **#N/A $0.00**  **$0.00 $0.00** 


### D 

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

**Price/ Unit**  **Purchase Price Net,**  **PIA Purchase** 

**Price Net, End Item**  1 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 2 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 3 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 4 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 5 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### "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 

## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 3 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 DRAFT **Technology Level:** OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

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

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

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: Motor - Generator, Electric**  

## Part Number: **021101-N0502-02** 

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

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

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

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

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

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

### End

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

### Material **Labor 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 Quo**  **te** 

### Modification Quote **Differential Quote (Quote S um**  **mary in clu**  **des costing for both T echnology Packages)** 

6 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 7 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 8 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 9 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 10 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 11 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 12 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 13 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 14 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 15 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 16 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 17 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 18 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 

### accounted for in T1 quote sheet. Thus component cost will only be included for Mark
- up Calculations. "Alpha
- Numeric Character" = Indicates purchase parts are brought in by T2/T3 Supplier for Subassembly.

19 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 20 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 21 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 22 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 23 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 24 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 25 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 26 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 27 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 28 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 29 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00** 30 **0 $0.00**  $0.00 **$0.00 $0.00**  **$0.00 Material**  **Labor $72.77**  **$54.45**
**Material Labor**  **Burden TMC**  **Scrap SG&A**  **Profit ED&T**  **Total Mark-up**  **$218.90 T1 or OEM Total Manufacturing Cost:**  **$72.77 $54.45**  **$91.68 $218.90**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $218.90** 

**T1 or OEM Mark-Up Rates:**
----- ----- ----- ----- 0.70% 7.00% 8.00% 4.00% 19.70% **(SAC) &T1 or OEM Mark-Up Values:**  **0.00**
----- ----- ----- **$1.53 $15.32**  **$17.51 $8.76**  **$43.12 Base Cost Impact to Vehicle:**  **$72.77 $54.45**  **$91.68 $218.90**  **$1.53 $15.32**  **$17.51 $8.76**  **$43.12 $262.02**  **$0 $0**  **Packaging Cost: $0.10**  **Net Cost Impact to Vehicle: $262.12** **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** **/ N** **u m** **b e** **r o** **f P** **a r** **t s** **p e** **r P** **a l** **l e** **t /** **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: Option 1 **3 1**  

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



### Reference Packaging Database for Additional Information Maximum Pallet Stack Height = 100" Pallet Options Option1: 48"(122cm)x45"(114cm)x34"(86cm) **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:**  **$0.098 $195,800**  **0.00% 2,250,000**  **60 5.00%**  $1,100 **178** 324 **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: $0.098**  

### Packaging Type: Option 1 Part Size: OD 180 x 80 Height Parts/Layer: 6 x 6 Number of Layers: 9 Option1: 48"(122cm)x45"(114cm)x34"(86cm) Investment $200 US funds (Mike S.) Assume Plastic Returnable Last 5 Years Option2: Vacuum Form Pack Made from 1/4" HDPE (Approx. Same Pallet size as Option #1. (Mike S. 020909) Investment $20K for tool Piece Price, 6" Pallet Base $100/Base Piece Price, Tier Pad $40/Pad Option3: Smaller Totes Approx 20"(508 mm)x12"(300mm)x12"(300mm) Package: 7 Layers of 6 on single Pallet Base. Cost per Tote: $75/Tote Cost per Base: 6" Pallet Base, $100/Base 

## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 4 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 DRAFT **Technology Level:** OEM Operating Pattern (W eeks/Year): OEM Plant Location: **Vehicle Class: Mid to Large Size Passenger Vehicle, 4-6 Passengers**  

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

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

## System Description: **2010 Ford Fusion, 2.5L Atkinson Cycle, I4, 156hp (191 Net), Mild HEV (Electric Motor 60kW, Battery 275V, Nominal Pack Capacity 5.5Ah, 1.51kWh)** 

## Annual Component Volume: Shipping Method: **Component Description: Motor - Generator, Electric**  

## Part Number: **021101-N0502-02** 

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

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

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

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

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

**Classification Material** 

**Specification Labor** 

**Classification Burden** 

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

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

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

### End

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

### Material **Labor 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 Quo**  **te** 

### Modification Quote **Differential Quote (Quote S um**  **mary in clu**  **des costing for both T echnology Packages)** 



### 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



## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 5 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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 Motor - Generator, Electric 021101-N0502-02



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



### 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 k** **t 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 R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r**

**$91.68 $218.90**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 5**  **2 10**  **100 47**  **4700 96**  **37.60 85%**  **113 31.96**  - - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0!** 

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

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

## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 6 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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.



### 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 k** **t 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 R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r** 

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

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


## Purchase Part - Commodity ( Value taken from Purchase Part Database) **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 5**  **2 10**  **100 47**  **4700 0**  **#DIV/0! 85%**  **0 #DIV/0!** 
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0! $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **5 2**  **10 100**  **47 4700**  **0 #DIV/0!**  **85% 0**  **#DIV/0!**
- - - - **1.0 1.0**  **#DIV/0!**

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

## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 7 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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.



### 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 k** **t 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 R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r** 

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

**$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$0.00 Burden**  **TMC Scrape**  **SG&A Profit**  **ED&T Mark-up**  **Total $91.68**  **$218.90 $0.00**  **$0.00 $0.00**  **$0.00 $0.00**  **$218.90 2** 

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



## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 8 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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.



### 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 k** **t 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 R** **e s** **u l** **t i** **n g** **P i** **e c** **e s** **/ H** **o u** **r** 

### 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**



## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 9 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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 Motor - Generator, Electric 021101-N0502-02



### 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 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!**
-



## 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!**
- 

## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 10 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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 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!**
- 

## 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!**
-


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



## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 11 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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 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** 



## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411

## Page: 12 of 12 

# Manufacturing Assumption and Quote Summary Print Date:8/30/2012 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 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** 



## Fi le: 09000064810ec171.xls EPA Contract: EP-C-07-069 WA1-3 PROPRIETARY and CONF IDENTIAL Fo rm Author: G. Kolwich (248)373-6000 Ext. 2411